Pressure Vesselsacc. to DGRL 97 / 23 / EG
Instruction Manual
Edition December 2006
Instruction manual • Pressure vessels
2
INSTRUCTION MANUAL FOR PRESSURE VESSELS ACCORDING TO DGRL 97/23/EG
Production year: *Pressure vessel production number: *Pressure vessel volume V: *Maximum allowed operating pressure PS: *Test pressure PT: *Permissible operating temperature TS min./max. *Medium: Air, Nitrogen, Helium,
(for CNG pressure vessels listed in table 2, only)(for Nitrox pressure vessels listed in table 3, only)
Specification: DGRL 97/23/EG and AD 2000Conformity evaluation process : Module H/H1Identification number of notified body : CE 0036
* refer to identification plate and/or embossed data on pressure vessel
The proper use of pressure vessels is indispensable for safe operation. This manual contains important notices andinformation regarding the installation, operation andmaintainanceof the pressure vessels; it is imperative that theoper-ating authority follows them.While every effort is made to ensure the accuracy of the particulars contained in this man-ual, the manufacturing company will not, under any circumstances, be held liable for any inaccuracies or the conse-quences thereof.
MANUFACTURER:
BAUER KOMPRESSOREN GmbHDrygalski Allee 37D--81477 MünchenTelephone: +49 89 78049 -- 0Telefax: +49 89 78049 -- 167
TABLE OF CONTENTS
1. Manufacturing information1.1 Declaration of conformity1.2 CE certificate1.3 Complaints1.4 Second--hand pressure vessels2. General2.1 Scope2.2 Modification or change2.3 Safety regulations2.4 Safety notices2.5 Maintenance, installation and repair work2.6 Storage2.7 Exclusion of liability3. Product description3.1 Application3.2 Pressure vessels for alternating stress4. Assembly
4.1 Mounting
4.2 Installation
4.3 Fittings
5. Operation
6. Tests
6.1 Test prior to start--up
6.2 Regular inspections
7. Maintenance
7.1 Spare parts
7.2 Fitttings to reduce the alternating stress of pressurevessels
8. General drawings
Edition December 2006© 2006 BAUER Kompressoren GmbH, Munich
All rights reserved.
Instruction manual • Pressure vessels
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1. Manufacturing information
1.1. Declaration of conformity
The declaration of conformity confirms the manufac-turer‘s first construction and pressure test for the pres-sure vessel. Each declaration of conformity includes anoperating manual acc. to DGRL 97/23/EG.
1.2. CE--certificate
The CE--certificate confirms that the pressure vesselsconform to pressure vessel directive 97/23/EG.
1.3. Complaints
The pressure vessel has been tested in the factory priorto delivery. Upon delivery it should immediately bechecked to make sure it‘s intact . Any damages causedby transport are to be reported immediately.Under no cir-cumstances are damaged pressure vessels allowed tobe put into operation.
1.4. Second--hand pressure vessels
Be particularly cautious with pressure vessels that havebeen bought second--hand and do not put them intooperation if their previous operating mode has not ex-plicitly been clarified.
2. General
2.1. Scope
This tecnical documentation is valid only for the pressurevessel delivered with this operating manual. You are notpermitted to transfer it to another or similar pressurevessel.
2.2. Modification or change
You are not allowed to make any modifications orchanges of the pressure vessel on your own authority.
2.3. Safety regulations
When starting--up and operating pressure vessels, youmust comply to national regulations. In Germany, theseare amongst others:-- Directive 97/23/EG (Pressure vessel--directive DGRL)as of 29.05.1997-- Operating safety regulation (BetrSichV) as of27.09.2002
2.4. Safety notices
This manual contains important notices and informationregarding the installation, operation andmaintainance ofthe pressure vessels that the operating authority is to fol-
low. For this reason it is imperative that the completedocumentation is handed--over to the specialist staff ofthe operators prior to assemby and start--up and madeavailable wherever it’s in use. The complete instructionmanualmust be carefully read by the specialist staff priorto assembly and start--up of the pressure vessel, thenkept in a safe place. Ignoring to observe the safety no-tices can result in being seriously dangerous for the staff,the pressure vessel or the environment.
2.5. Maintenance, installation and repair work
The operating authority is obliged to ensure that all main-tenance, installation and repair work is carried out byauthorizedandqualifiedspecialist staffwhichhaveprevi-ously acquired enough information by carefully studyingthe instruction manual. The responsibility and liability re-garding the equipment and assembly after start--up lieswith the operating authority.
2.6. Storage
The pressure vessels are to be stored in a closed, dryand clean room. Avoid any damage that could becaused, for example by any objects falling on them orpassing--by vehicles.
2.7. Exclusion of liability
If the following instructions and information are not ob-served, we exclude all liability. This exclusion of liabilityalso leads to the loss of any right to claim for damages.
This particulary applies in the case of• improper installation• improper application• any change or modification of the pressure ves-
sel• non--compliance to the safety notices• improper maintenance work• improper storage• corrosion resulting from not complying to the
above points
3. Product description
3.1. Application
The pressure vessel is to be used for drying or purifyinggases.
The operating safety can only be guaranteed when usedaccording to the regulations, with the intended operatingmedium and within the temperature and pressure limitsmarked on the vessels.
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Operating medium:
For classification of the pressure vessels themedia are divided into two groups:• dangerous and non--dangerous media.
For BAUER KOMPRESSOREN this classificationis applicable for the following media:
non--dangerous: air, nitrogen, heliumdangerous: CNG (compressed
natural gas)
Only the pressure vessels listed intable 2 are approved for use withCNG!
Only the pressure vessels listed intable 3 are approved for use with Ni-trox (max. oxygen content of 40%)and in BAUER B--Trox units, only!
3.2. Pressure vessels for alternating stress
Pressure vessels authorized for applicationwithalternat-ing stress can be operated under considerable fluctuat-ing operating pressure. In such cases the pressure canfluctuate between the atmospherical pressure and themaximum permitted operating pressure. Only thevessels listed in table 1 are authorized for applicationwith alternating stress according to AD2000--Merkblättern (instructions).
Pressure vessels that do not appear in the table arenot authorized for application with alternatingstress!
Due to the fluctuationof theoperatingpressure, pressurevessels for applicationwith alternating stress are subjectto an exceptional load. The lifetime of these vessels is li-mited to a maximum number of alternations of load. Analternation of load (or load cycle) is defined as the pres-sure fluctuation that occurs between the minimum andmaximum operating pressure (pressurization and de-pressurization). The difference that occurs betweenminimumandmaximumoperating pressure is definedasthe pressure variation range.
The allowed number of load alternations (also called al-lowed number of cycles) of the respective pressurevessels at the occuring pressure variation range is listedin table 1.
In order to ensure safe operation, when half of the al-lowed number of load alternations has been reached(alumimium vessels: 1/4 of the allowed number of loadcycles), the pressure vessel must be subjected to an in-ternal inspection in which the critically stessed vessel
areas are checked using appropriate testing methods.
On reaching the total allowednumberof loadalternationsthe vessel has to be exchanged and scrapped.Take written note of the amount of load alternations thathave be done if you do not have an automatic cycle--counter.
4. Assembly
4.1. Mounting
When mounting and operating pressure vessels, youmust comply to the relevant national regulations. In Ger-many this is, amongst others the operating safety regula-tion.Thepressure vessels areonly allowed tobeused forthe appropriate application, pressure stage and operat-ing temperature.
4.2. Installation
The installation is to be carried out by qualified specialiststaff. Make sure the pressure vessel and its fittings func-tion perfectly.
4.3. Fittings
Thepressure vessel has to beequippedwith appropriatesafety and test devices, which ensure that it is not poss-ible to operate it outside the allowed operating condi-tions. Pay attention to the right disposition and choice ofthe safety devices.In the caseof pressure vessels that are not authorized forapplication with alternating stress, you must use the ap-propriate fittings (e.g.: non--return valves, pressuremaintaining valves, ecc.) to make sure that they cannotbe subject to unauthorized alternating stress.Pressure vessels that are authorized for application withalternating stress have to be equipped with the appropri-ate fittings (e.g.: non--return valves. pressure maintain-ing valves, ecc.) to ensure that the allowed pressure vari-ation range is not exceeded.
5. Operation
With anything regarding operation, you have to complyto the relevant national regulations. In Germany theseare, amongothers things the operating safety regulation.
6. Tests
6.1. Test prior to start--up
Concerning the test prior to start--up, you have to complyto the relevant national regulations. In Germany theseare, among other things the operating safety regulation.
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6.2. Regular inspections
Concerning the regualr inspections, you have to complyto the relevant national regulations. In Germany theseare, among other things, the operating safety regulation.This sets the following maximum intervals for pressurevessels from category III or IV for gaseous mediums Air,N2 und He.Interior examination: 5 YearsStrength test: 10 YearsThese intervals are also valid for our pressure vesselsfrom category IV for the medium natural gas.The inspections have to be performed by a surveyingauthority.We recommend the same intervals for pressure vesselsof category II and I, or according to article 3, para. 3 forthe media air, N2 and He as well as for pressure vesselsof category II, II, or I according to article 3, para. 3 for themedium natural gas. Inspection of these vessels shouldbe performed by an expert or by a surveying authority.If national regulations in other countries do not specifyregular inspections, we recommend to proceed accord-ing to the German operating safety regulation (Be-triebssicherheitsverordnung).Pressure vessels that are not subject to alternatingstress canbeusedas longas the inspections, carriedouton a regular basis, do not uncover any safety--relatedfaults.In order to ensure safe operation, when half of the al-lowed number of load alternations has been reached(alumimium vessels: 1/4 of the allowed number of loadcycles), pressure vessels used for application with alter-nating stressare tobeadditionally (independent of the in-tervalsabove) subjected toan interior inspection inwhichthe critically stessed vessel areas are checked using ap-propriate testing methods.After reaching the total allowed number of load alterna-tions the vessel has to be exchanged and scrapped.Weadvise, in the case of aluminiumvessels that they areexchanged at the latest after 15 years.
7. MaintenanceCheck your pressure vessels inside andoutside for dam-age and corrosion.
Never open or loosen vessel coveror tube connection parts under pres-sure. Always depressurize vessel orunit first.
7.1. Spare parts
To guarantee safe operation use only original BAUERspare parts. If a part of the vessel subject to pressure is
damaged the whole pressure vessel has to be ex-changed. Individual vessel parts subject to pressure arenot available as spare parts since tests and documenta-tion are only done for the whole vessel.
7.2. Fitttings to reduce the alternating stress ofpressure vessels
In order to avoid pressure vessels being subject to un-authorized alternating stress, fittings that limit the pres-sure fluctuations of the pressure vessel must have theiroperatabiliity and internal and external tightnesschecked. These include in particular non--return valvesmounted before the pressure valve and pressure main-taning valves mounted after the vessels; both are meantto avoid or reduce unwanted pressure decreases in thepressure vessels in the case of a reduction in pressurebefore or after the vessel.
8. General drawings
The manufacturer keeps a manufacturing drawing and itcan be sent to you on request. For the drawing number,refer to the conformity certificate.
Instruction manual • Pressure vessels
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Table 1 Load cycles -- synoptical table for pressure vessels
Part no. Pressure variation range Max. allowed no. of load cycles
014976014938055093055144055283
0--350--0 bar 2.000
055106056365
0--350--0 bar 69.000
055719--EU055720--EU055721--EU060261--EU060294--EU
0--420--0 bar0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar0--200--0 bar0--180--0 bar
16.49219.29522.88127.59233.89542.63055.23074.450105.540160.890291.620675.000
w/o limitation058416--EU065519--EU
0--500--0 bar 65.000
061081--EU061082--EU061223--EU061224--EU061685--EU062042--EU090950--EU090960--EU090970--EU81423--EU
140--350--140 bar140--330--140 bar140--310--140 bar140--290--140 bar140--270--140 bar140--250--140 bar140--230--140 bar
4.0006.99012.65023.83046.95097.450215.000
063716--EU 0--120--0 bar0--100--0 bar
53.00064.000
063859--EU 0--32--0 bar 64.00006279106463206652206652306761207717007738707738878189782237822478269806908110681788817988179981800
0--100--0 bar 85.000
Instruction manual • Pressure vessels
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Max. allowed no. of load cyclesPressure variation rangePart no.
064126--EU80476--EU
0--350--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar0--200--0 bar0--180--0 bar
49.24555.47071.92296.880137.270208.640351.540697.8001.854.000
w/o limitation
064185
0--22--0 bar0--20--0 bar0--18--0 bar0--16--0 bar
751.160999.8001.372.0001.953.000
065481--EU065482--EU065483--EU065484--EU065485--EU065486--EU067920--EU091020--EU091030--EU091040--EU
140--420--140 bar140--410--140 bar140--390--140 bar140--370--140 bar140--350--140 bar0--420--0 bar0--410--0 bar0--390--0 bar0--370--0 bar0--350--0 bar
5.7006.7009.40013.60020.0002.2002.5003.4004.6006.500
065974--EU
0--500--0 bar0--480--0 bar0--460--0 bar0--440--0 bar0--420--0 bar0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar0--200--0 bar
26.00029.00034.00039.00046.00054.00066.00082.000100.000130.000180.000260.000400.000690.0001.400.000
w/o limitation067105--EU067106--EU091010--EU
140--350--140 bar 2.000
067571069934
0--50--0 bar 40.000
074194
0--200--0 bar0--180--0 bar0--160--0 bar0--140--0 bar0--120--0 bar0--100--0 bar
169.480325.900681.8001.573.0004.079.000
w/o limitation
Instruction manual • Pressure vessels
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Max. allowed no. of load cyclesPressure variation rangePart no.
07478981841
0--200--0 bar0--180--0 bar0--160--0 bar0--140--0 bar0--120--0 bar0--100--0 bar0--80--0 bar
62.500117.160241.620556.8001.463.0004.513.000
w/o limitation
075630
0--420--0 bar0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar0--200--0 bar
34.57341.52450.80263.65381.920109.250152.660228.000372.520701.6001.681.000
w/o limitation
075631--EU090100--EU090110--EU80142--EU82970--EU82981--EU83247--EU
0--420--0 bar0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar
55.46068.25185.830108.470143.190197.270287.810455.000810.0001.744.000
w/o limitation
076400--EU
0--350--0 bar0--330--0 bar0--310--0 bar0--290--0 bar0--270--0 bar0--250--0 bar0--227--0 bar
74.750100.000140.520210.610346.410657.000
w/o limitation077634--EU
077159--EU--V001077159--EU--V002
82571--EU82577--EU--V00182577--EU--V002
0--350--0 bar0--230--0 bar
4.00035.000
078085--EU078086--EU
0--350--0 bar0--340--0 bar0--330--0 bar0--320--0 bar0--310--0 bar0--300--0 bar
11.70014.30017.70022.00027.50034.800
78470
0--420--0 bar0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar
166.230225.570322.720492.720831.1001.609.000
w/o limitation
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Max. allowed no. of load cyclesPressure variation rangePart no.
79141
140--350--140 bar140--310--140 bar140--270--140 bar140--230--140 bar0--350--0 bar0--310--0 bar0--270--0 bar0--230--0 bar
46.00085.900175.000400.00025.00039.60066.900123.000
79468--EU090002--EU
0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar0--200--0 bar
31.97939.10448.57762.10881.996113.827166.485266.714479.5781.090.909
w/o limitation79873--EU82568--EU
0--350--0 bar0--230--0 bar
3.60020.000
80474--EU 0--32--0 bar 107.000
8113081777
0--200--0 bar0--180--0 bar0--160--0 bar0--140--0 bar0--120--0 bar
278.500539.8001.126.0002.528.000
w/o limitation
83111--EU84577--EU
0--350--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar
127.380143.190197.270287.810455.000810.0001.744.000
w/o limitation83487--EU83488--EU83489--EU83490--EU83491--EU83492--EU83493--EU83494--EU83495--EU83487--EU
140--500--0 bar140--480--0 bar140--460--0 bar140--440--0 bar140--420--0 bar140--400--0 bar140--380--0 bar
118.140164.510244.560395.230732.5001.664.000
w/o limitation
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Max. allowed no. of load cyclesPressure variation rangePart no.
83544--EU
0--500--0 bar0--480--0 bar0--460--0 bar0--440--0 bar0--420--0 bar0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar
36.26542.09050.00058.96072.49092.540121.800167.460242.200381.300673.1001.399.000
w/o limitation84757 0--70--0 bar 85.000
090058--EU090060
090300--EU
0--350--0 bar0--320--0 bar0--300--0 bar0--290--0 bar
85.000150.000170.000200.000
090080 0--350--0 bar 100.000
090320--EU83270--EU
0--420--0 bar0--400--0 bar0--380--0 bar0--360--0 bar0--340--0 bar0--320--0 bar0--300--0 bar0--280--0 bar0--260--0 bar0--240--0 bar0--220--0 bar
40.48548.98360.46176.48099.760135.360193.600297.820510.1001.040.000
w/o limitation
091190--EU091200--EU091210--EU
0--350--0 bar0--330--0 bar0--310--0 bar0--290--0 bar0--270--0 bar0--250--0 bar0--230--0 bar0--210--0 bar0--190--0 bar0--170--0 bar0--150--0 bar0--130--0 bar
16.86420.68725.85133.46334.21245.92566.011102.690182.442391.6081.270.808
w/o limitation
091220--EU 0--350--0 bar0--239--0 bar
180.000w/o limitation
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Table 2 Pressure vessels approved for medium CNG(Natural gas group H or L DVGW, worksheet G260/I and G260/II, only)
Part No.
Oil and water separators078085--EU 80142--EU078086--EU 80474--EU090300--EU 80476--EU63716--EU 82970--EU79468--EU 82981--EU
Filters83123
090002--EU
Intermediate separators062791 78269064632 80690066522 81106066523 81130067612 81777074194 81798074789 81799077387 81800077388 8184178189 84757
Others074552--EU068316
Table 3 Pressure vessels approved for medium Nitrox (max. oxygen content of 40%)and in BAUER B--Trox units, only.83123
Part No.
Oil and water separators84577--EU
Filters061082--EU061224--EU061685--EU062042--EU090960--EU090970--EU79873--EU
BAUERKOMPRESSORENGmbHSystemwerkPostfach 710260 D--81452 München
Tel. +4989--78049--0 Fax 089/78049167Internet: www.bauer--kompressoren.de
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