CÔNG TY CỔ PHẦN XI MĂNG THĂNG LONG

THANG LONG CEMENT JSC

Quang Ninh, ngày 14 tháng 10 năm 20

Quang Ninh, October 14th, 2020

Report piston accumulator STATUS OF RAW MILL

Báo cáo về tình trạng bình tích năng nghiền liệu

1, Piston Accumulator status / Tình trạng Bình tich năng

Currently have two the Piston Accumulator was scratched, See picture:
Hiện tại có 2 bình tích năng bị xước lòng, như hình ảnh sau:
Because the Piston Accumulator was scratched, so we cannot use it

Do bình tích năng bị xước nên không thể dùng được

2, Repair plan / phương an sửa chữa

- We have PR10175 service repair

Mechanical area 1 Maintenacce Production

section Departement Director
bình tích năng
 dài 2610mm
 đường kính ngoài 280mm
 đường kính trong 250mm
yêu cầu :
sau khi làm xong thử áp đến 250 bar không bị rò rỉ
bên B cung cấp thêm 1 bộ gioăng
 Operating Manual

Piston Accumulator
with CE sign

Bolenz & Schäfer GmbH

P.O. Box 1261
35202 Biedenkopf-Eckelshausen
Germany

Phone: ++49 (0) 64 61 / 933 – 0

Fax: ++49 (0) 64 61 / 933 – 161
E-mail: sales@bolenz-schaefer.de Edition 11/02
Internet: www.bolenz-schaefer.de
 Pressure Equipment

Pressure Equipments - Identification

in accordance with the serial number on the type plate and
the according report

see

Acceptance Report
directive 97/23/EG for pressure equipments, Module G
for fluids of group 2

TÜV Technischen Überwachung Hessen GmbH

(Department of Transport)

(and taking set of drawings with serial number as a basis)

Explanation
Piston accumulator / pressure transmitter - pressure equipment

Translation
If sold to a country in the EEA, this operating manual 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.

DSS-G21
 Pressure Equipment

0 Contents

0.1 Contents
0 Contents 1
0.1 Contents 1
0.2 Table of figures 1
1 Designated application 2
1.1 Overview 2
1.2 Notes for designated application 2
2 Function 3
2.1 General functional description 3
2.2 Filling and checking the pressure equipment
(by qualified technicians) 3
2.3 Filling / emptying process 5
2.3.1 Preparing the filling process 6
2.3.2 Filling with nitrogen 6
2.3.3 Termination of the filling procedure 7
2.4 Depressurization 7
2.4.1 Depressurization of the oil side is to be carried out by the customer 7
2.4.2 Depressurization of the gas side 7
3 Safety 8
3.1 Notes / Explanations 8
3.2 CE sign/type plate 8
3.3 Safety system 9
3.4 Safety precautions (to be carried out by the customer) 9
3.5 Responsibilities of the customer 9
3.6 Safety inspections 10
4 Dangers 10
4.1 General warnings 10
4.2 Spare and wearing parts 10
4.3 Cleaning, maintenance, repair work 11
5 Installation 11
5.1 Scope of supply 11
5.2 Delivery 11
5.3 Transport and packing 12
5.4 Intermediate storage (packed) 12
5.5 Storage / packing for onward transport 12
5.6 Assembly / Commissioning 13
6 Maintenance 14
6.1 General information on maintenance 14
6.2 Returning checks and test time periods 15
7 Troubleshooting 15
8 Emergencies 15
9 Dismounting / Disposal 16

0.2 Table of figures

Fig. 1-1 Overview pressure equipment 2
Fig. 2-1 Filling and testing kit (NW 6) for BSD filling valve 5
Fig. 2-2 Filling and testing kit (NW 2) for Minimess filling valve 5

DSS-G21 1
 Pressure Equipment

1 Designated application

1.1 Overview

gas room
oil room

Fig. 1-1 Overview pressure equipment

The pressure equipment consists of the following components:

1 Casing tube
2 Piston inclusive seals
3 End caps
4 End cap seals on oil side
5 End cap seals on gas side
6 Threaded ring
7 Gas non-return valve (not necessarily included - depending on order)
8 Blanking plug (not necessarily included - depending on order)

1.2 Notes for designated application

The piston accumulator/pressure transmitter (pressure equipment) was

manufactured exclusively to receive and release hydraulic fluids under pressure
as a component in hydraulic plants in industrial applications.

Any other use or modification of the machine without the written consent of the
manufacturer is deemed improper.

The manufacturer accepts no liability for resultant damage.

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 Pressure Equipment

On the fluid side, the pressure equipment may solely be operated using non-
corrosive fluids of group 2 and on the gas side with N2. This also applies in
connection with the range of transient pressure mentioned in the "Acceptance
Report" and the permitted stress reversals. These details are with regard to the
pressure equipment being completely emptied and filled 20 times.

Proper use of the machine in accordance with its designated application

includes compliance with the manufacturer's operating, maintenance and repair
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.

The commissioning is strictly forbidden until it has been determined that the
entire system in which the pressure equipment is being built in corresponds with
the EC directives.

The fluids needed for operation of the pressure equipment in compliance with
its designated application are procured and used by the customer. Proper
handling of these fluids and the related dangers are the sole responsibility of the
customer.

For special applications or in case of uncertainties request a written acceptance

from the 'manufacturer'.

2 Function

2.1 General functional description

BSD pressure equipments are cylindrical pressure vessels with a separative
element between the gas and fluid space. They are used in hydraulic systems
among others as energy accumulator. If the fluid pressure is higher than the gas
filling pressure the hydraulic energy is stored in form of fluid. This can be used for
operating processes in case the fluid pressure lowers below the compressed gas
pressure.

2.2 Filling and checking the pressure equipment (by qualified technicians)

While filling or after filling N2 gas check all screw fittings, shut-off devices,
connecting and junction points for tightness using a foaming agent.

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 Pressure Equipment

BSD pressure equipments may only be filled with nitrogen of class 4.0. The filling
takes place by means of an approved filling and testing kit (fig. 2-1 or fig. 2.2),
which can be obtained from us. The pre-load pressure depends on the ambient
temperature (isochore behavior of N2, see following table) and should be 5 bar
below the minimum operating pressure at maximum ambient temperature (if there
are no other specifications).

Never use oxygen or other combustible gases for filling the piston accumulator!

Isochore behavior of N2

Determination and control of the pre-

load pressure P0 at different ambient
temperatures

General information
The pre-load pressures P0 mentioned are
referring to a room temperature of + 20 °C.
If the real temperature differs to + 20 °C by
the time of loading or control, it can be
found from the diagram what pressure
must be pre-loaded or be available.

Example
A gas system with a gas pressure of 155
bar and a gas temperature of + 20 °C is
given. When the gas temperature changes
to + 35 °C the intersection (155 bar at + 20
Pressure [ bar ]

°C) should be moved parallel to the next

pressure temperature lapse until the
perpendicular temperature line meets + 35
°C. In the example mentioned a pre-load
pressure P0 of 166 bar must be pre-loaded
or should be found.

Temperature [°C]

4 DSS-G21
 Pressure Equipment

Filling and testing kit (NW 6) Filling and testing kit (NW 2)
for BSD filling valve for Minimess filling valve

4 5

1
2 3

Fig. 2-1 Filling and testing kit (NW 6) Fig. 2-2 Filling and testing kit (NW 2)
for BSD filling valve for Minimess filling valve

The filling and testing kit consists of:

1 Accumulator connector
2 Cylinder connection
3 High-pressure hose
4 Spindle
5 Thread
6 Hose connection

2.3 Filling / emptying process

Filling and testing kits may only be used according to the following instructions by
qualified personnel who are specially trained.
For carrying out the instructions (filling) please see the circuit diagram and parts
list.

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 Pressure Equipment

2.3.1 Preparing the filling process

Filling by means of the BSD filling valve Filling by means of the Minimess filling valve
(NW 6) fig. 2-1 (NW 2) fig. 2-2

1. Unscrew the blanking plug (fig. 1-1, pos. 8) and 1. Screw cylinder connection (fig. 2-2, pos. 2) on to a
remove the seal on the blanking plug. commercial nitrogen gas cylinder. The gas cylinder
2. Turn the spindle (fig. 2-1, pos. 4) of the valve is closed.
accumulator connector (fig. 2-1, pos. 1) of the
filling and testing kit all the way to the left to its 2. Connect the high-pressure hose and the cylinder
stop. connection.
3. Use the removed seal for the accumulator
connector and screw the thread (fig. 2-1, pos. 5) 3. Unscrew the sealing cap of the Minimess filling valve on
into the pressure equipment instead of the the pressure equipment.
blanking plug.
4. Screw the cylinder connection (fig. 2-1, pos. 2) 4. Connect the high-pressure hose with the filling valve of
on to a commercial nitrogen gas cylinder. the pressure equipment.
5. Connect the accumulator connector and the
cylinder connection with the corresponding high- 5. The accumulator can be filled with nitrogen.
pressure hose (fig. 2-1, pos. 3).
6. Now turn spindle of part 1 all the way to the right
to its stop. This way the non-return valve (fig. 1-
1, pos. 7) is opened and the pressure equipment
can be filled with nitrogen.

Same procedure for both equipments from point 7 to point 10.

2.3.2 Filling with nitrogen

7. Open valve of the gas cylinder until the required pre-load pressure on the
pressure gauge is reached. The required pre-load pressure can also be read
from the gas side pressure gauge when the valve is open, should this exist
on the system. For reading the pressure P0 close the cylinder valve from time
to time.
8. Since the pressure P0 depends on the temperature and the temperature of
the nitrogen changes during the filling procedure the final measurement of
the pre-load pressure can only take place after the temperature of the gas
has compensated with the environment. For this you have to wait a while (15
min.).
9. If the pre-load pressure P0 is too high reduce the pressure to the correct
value by means of the pressure discharge valve. The gas cylinder valve
must be closed.

Caution!
If the pressure of the N2 pressure gas cylinder is higher than the maximum
permissible pressure of the pressure equipment and if there is no pressure
fuse-protection on the pressure equipment, insert a pressure control which
protects the pressure equipment.

6 DSS-G21
 Pressure Equipment

2.3.3 Termination of the filling procedure

10. For terminating the filling procedure close the gas cylinder valve.
11. Turn the spindle (fig. 2-1, pos. 4) of the accumulator connector
(fig. 2-1, pos. 1) of the filling and testing kit all the way to the left to its stop
and the non-return valve in the pressure equipment closes.
12. The depressurization of the accumulator connector, cylinder connection and
high-pressure hose (fig. 2-1) takes place by opening the pressure release
valve on the cylinder connection.
13. Unscrew the accumulator connector and the cylinder connection.
14. Tightly screw in blanking plug with gasket (see point 1 and 3) again. Only use
original screw plugs with depressurization.

Possible occurring problems and solutions:

If a balance of pressure between the pressure equipment and N2 gas cylinder can
be created prior to reaching the pre-load pressure the procedure of filling the
pressure equipment cannot be continued (nitrogen gas cylinder does not have
enough pressure anymore).

Changing the N2 gas cylinder:

1. Carry out points 10 to 12; loosen screw setting of the cylinder connection (fig.
2-1) on the empty gas cylinder and attach the cylinder connection to the new
N2- gas cylinder.
2. Now you can continue filling the pressure equipment as described starting
from point 6.

2.4 Depressurization

2.4.1 Depressurization of the oil side is to be carried out by the customer

2.4.2 Depressurization of the gas side

Discharging by means of the BSD filling Discharging by means of the Minimess

valve (NW 6) fig.2-1 filling valve (NW 2) fig.2-2

1. See working procedure 1 to 3, chap. 2.3.1 1. Connect the high-pressure hose and the cylinder
connection.
2. Screw accumulator connector (fig. 2-1, pos. 1)
into the connection of the pressure equipment
hand-tight. 2. Unscrew the sealing cap of the Minimess filling valve
on the pressure equipment.
3. Slowly turn the spindle (fig. 2-1, pos. 4) to the
right. The non-return valve (fig. 1-1, pos. 7) in the 3. Connect the high-pressure hose with the filling valve
pressure equipment opens and gas flows to the of the pressure equipment.
cylinder connecting piece (fig. 2-1, pos. 2).

4. The gas can be discharged by turning the 4. By turning the depressurization screw to the left on
depressurization screw to the left. the cylinder connecting piece (fig. 2-1, pos. 2) you
can clearly hear the gas discharging.
5. Check if the pressure equipment is depressurized
on the gas side. If this is the case the pressure 5. Check if the pressure equipment is depressurized on
gauge display shows 0 bar. Leave the gas side. If this is the case the pressure gauge
depressurization screw open. display shows 0 bar. Leave depressurization screw
open.
6. If there is still pressure in the system repeat the
procedure. 6. If there is still pressure in the system repeat the
procedure.

DSS-G21 7
 Pressure Equipment

3 Safety

3.1 Notes / Explanations

Operating manual mandatory

framed and marked with a book symbol.

Dangers
framed and marked with a warning triangle.

Notes
framed and marked with a hand symbol.

The vessel is already filled with N2 gas according to the indications on the pressure equipment.

3.2 CE sign/type plate

The pressure equipment is equipped with a type plate and CE sign. The essential
technical details are indicated on it.

Whenever consulting us it is essential that the following details are stated

correctly:

• Name of type
• Serial number
• Year of construction

8 DSS-G21
 Pressure Equipment

3.3 Safety system

The safety system can be part of the delivery (see shipment documents) or it is
part of the assembly carried out by the customer.

In any case the safety system is necessary and must be checked for efficacy
prior to commissioning.

3.4 Safety precautions

(to be carried out by the customer)

The customer must instruct his operating and maintenance personnel in the use
of the piston accumulators and ensure that the safety precautions are being
adhered to.

In principle, the responsible specialized superiors must instruct the operating,

maintenance and servicing personnel prior to employment and first initial start-up
of the pressure equipment and from that date on in appropriate time intervals but
at least once a year. Maintenance, servicing as well as instruction measures must
be recorded in a control book.

Qualified technician (definition based on EN 60204-1)

• A person who, on account of his technical training, know-how, experience and
knowledge of relevant standards, is able to assess the work assigned to him
and identify potential dangers.

3.5 Responsibilities of the customer

In the EEA (European Economic Area) national implementation of the

framework directive (89/391/EEC) and corresponding individual directives, in
particular the directive (89/655/EEC) on the minimum regulations for safety and
health protection in the use of work materials and tools by employees at work,
as amended, are to be observed and adhered.

DSS-G21 9
 Pressure Equipment

In addition to this, he must observe local laws and regulations on

- personnel safety (accident prevention regulations)
- safety of work materials and tools (safety equipment and maintenance)
- disposal of products (laws on wastes)
- disposal of materials (laws on wastes)
- cleaning (cleaning agents and disposal)
- environmental protection.

The customer must ensure that local regulations (e. g. acceptance test etc.) were
observed during installation and commissioning of the machine if this work was
carried out by the customer himself.

3.6 Safety inspections

The scope of delivery encloses the following documents:

- Testing procedure according to the pressure equipment directives

(manufacturer) with the operation data as per acceptance report by TÜV
(Department of Transport).

4 Dangers

4.1 General warnings

The maximum and minimum operating data indicated on the type plate and in this
manual must not exceed or remain under.

The assembly of the pressure equipment must be carried out in a way that the
operating personnel is not endangered by leaking operating material should a
reaction of the safety equipment parts occur.

Constructional changes
Constructional changes on the pressure equipment may not be carried out.
Mechanical subsequent treatment or welding is prohibited.

4.2 Spare and wearing parts

The manufacturer accepts no liability for damages arising from fitting parts that
have not been tested and approved by him.

10 DSS-G21
 Pressure Equipment

Pressure maintaining components may only be replaced by the manufacturer or

on his approval.
A new acceptance test by an appointed authority is necessary!

4.3 Cleaning, maintenance, repair work

Cleaning, maintenance or repair work may only be carried out by qualified

technicians.
Depending on the applications the system must be depressurized on the oil side
and secured so that it cannot be switched back on again. If working on gas side
components then a depressurization on the gas side has to be carried out (see
chap. 2.4.2).

5 Installation

5.1 Scope of supply

For the pressure equipment/equipment components you will receive technical

reference material containing an operating manual, set of drawings and
acceptance report of the appointed authority as well as the declaration of
conformity.

5.2 Delivery

Receiving inspection:
- Check the shipment against the delivery note to ensure that it is complete!

Damages:
- Check delivery for damages (visual inspection)!

Complaints:
If the shipment was damaged during transit:
- Immediately contact the last carrier!
- Keep the packing material (in case the carrier wants to inspect it or the
shipment has to be returned)

DSS-G21 11
 Pressure Equipment

5.3 Transport and packing

For the delivery (by qualified personnel) suitable means of transport and transit
routes must be used. Make sure that the pressure equipment will not be damaged
on the outside. In any case, when returning the shipment to the manufacturer
make sure that the equipment is delivered depressurized.
For onward transport and set-up use suitable means of transport such as a crane
or fork-lift truck in connection with suitable belts which are looped around the
cylinder tube. The thread holes drilled frontal in the accumulator may only be
loaded to the total weight described in the table. It is advisable to secure it using
an additional belt. For the weight of the pressure equipment or the equipment
components please see diagram. Pay attention to the point of gravity.

Permissible total weight of the pressure equipment when fastening hitching

means in the adjusting nut (depending on the accumulator series):

Series Fastening borings Admissible total weight of the

(diameter) pressure equipment (see drawing)
100 2xM8 500 kg
180 2 x M 12 1500 kg
250 2 x M 12 1500 kg
360 2 x M 16 2000 kg

The crane or fork-lift truck must be constructed to bear the total weight of the
transport unit!
The driver must have a license for conducting the crane and/or fork-lift truck.

5.4 Intermediate storage (packed)

The pressure equipment and spare and replacement parts are designed for a
storage period of three months from delivery.

Storage conditions
Closed and dry room according to the designated operating conditions.

5.5 Storage / packing for onward transport

The storage of the pressure equipment and, if necessary, accessories must take
place in a way that the goods are protected against outside influences and
damages.

Prior to shipment, the manufacturer makes sure that all components of the
pressure equipment are protected against corrosion for an appropriate storage
period (3 months) in a suitable way.

12 DSS-G21
 Pressure Equipment

Optimum short-term storage conditions:

- dry rooms
- protected against mechanical loads

For longer storage times or unfavorable storage conditions protective measures

may become necessary the operator of the pressure vessel is responsible for.
During transport and storage the connection openings of the pressure equipment
must be closed to avoid dirt and dampness getting into the equipment and
formation of perspiration water.
On receipt of the pressure equipment the future operator of the system takes
responsibility for taking care of storage in accordance with the instruction. In this
case pay attention to avoiding longer storage or transport times while the
machine is still packed in packing material.

Packing for onward transport (change of location)

For an intended onward transport the pressure equipments and its components
must be packed in a way that mechanical damages can be avoided.

Prior to the packing for onward transport the components may need to be
decontaminated. For this follow the data sheets of the media/fluids the parts
may come into contact with. Pay attention to the notes about transport and on
the drawing.

5.6 Assembly / Commissioning

Set-up/installation
Assembly of the pressure equipment is to be carried out by qualified personnel
and must be specially trained for this kind of work.
A vertical arrangement with the oil side at the bottom is recommended. A different
arrangement leads to increased wear.

For inspection and test time periods also consider chap. 1.2 section 4.

For fastening the equipment use appropriate fixing elements in accordance with
the static and dynamic load.
The pressure equipment must not be welded or soldered; no mechanical
encroachment may be carried out.
No additional forces and/or moments may affect the pressure equipment. The
pressure equipment must not be subject to any kind of flames or electrical and/or
magnetic fields which may lead to heating.
When attaching the consoles/ring make sure that the case of the pressure
equipment does not deform or becomes damaged in some other way.

DSS-G21 13
 Pressure Equipment

Heavy damages can cause an explosion of the vessel.

The pressure equipment may only be set up in rooms that are protected
against lightning strikes and earthquake.

For a safe fastening of the single components use the fastening elements
recommended by the manufacturer. To assure the steadiness of the machine the
operator has to make sure to use suitable securing of the fixing device (using
dowels and screws).
For the required information, instructions and technical specifications needed to
set up the pressure equipment see the operating manual and the general plan.

Before assembly:
- Check delivery for damages during transit and with it assurance of the
technical soundness.
- Instruct the qualified personnel

Before commissioning the operator must:

- Check for complete technical documents according to chap. 5.1.
- Completion of the feeding and outlet systems and of the equipment parts
with safety function of the system in which the pressure equipment is built
in.
- Check for safe function of the built-in fittings.

Prior to the initial start-up of the pressure equipment the operator has to arrange
the acceptance inspection of the complete system.
When filling and emptying pay attention to chap. 2 and chap. 4.

Dismounting the pressure equipment

Before dismounting the equipment check and make sure the oil and gas side are
without pressure.

6 Maintenance

6.1 General information on maintenance

After filling the pressure equipment with N2 gas it is extensively maintenance-free.
To guarantee a trouble-free work and a long life of the pressure equipment the
following maintenance work must be carried out according to a maintenance plan
determined by the operator:
A monthly inspection is recommended. The intervals can accordingly be adapted
to gained experience.
- Check accumulator fixings
- Check pipe connections
- Check and value the condition of the fittings, safety systems and seals, etc.
- Check all screws, shut-off devices, connecting and junction points using
foaming agents for gas tightness
- Check gas pre-load pressure.

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 Pressure Equipment

6.2 Returning checks and test time periods

Test time periods
In Germany the pressure equipment is subject to the Industrial Safety Regulation.
(§14)
The periods for returning inspections are determined in the Industrial Safety
Regulation § 15.
(Pay attention to the according national directives of the set-up country, see chap.
3.4).
After 10 years at the latest, the pressure equipment must undergo an internal and
external inspection with a following print sample.

Inducement and performance

The operator must induce the adherence and performance of the test time
periods.

7 Troubleshooting

By qualified personnel only

Problem Cause Possible solution

Pressure equipment system Shut-off valve is closed; Open shut-off valve

delivers no hydraulic oil
depressurization is open close depressurization

gas side pressure too low check pre-load pressure

Hydraulic pressure is too low Shut-off valve is closed. Open shut-off valve

Pump is not delivering Check pump for operatability, repair if

necessary

Gas safety valve reacts Gas side pressure too high Check pre-load pressure
Check adjustments of the system
Gas temperature has strongly
increased due to operation Search for cause of temperature rise

Fluid has overflowed Discharge pressure equipment

8 Emergencies

This pressure equipment is a passive system that does not have any own drives.
The stored energy is input or output by a customer's active system connected to
it.
Therefore it is appropriate that the operator determines and documents in the
work instructions when emergency measures such as actuating the emergency
off systems or triggering/releasing the depressurization quick are to be taken.

DSS-G21 15
 Pressure Equipment

9 Dismounting / Disposal

Before disposal, make sure that the equipment is free of pressure on the gas and
oil side.

Sort the pressure vessel according to material that is to be disposed in

accordance with the local environmental protection regulations.

Decontaminate and dispose contaminated parts in accordance with the local

environmental protection regulations.

Collect media residuals and dispose in accordance with the manufacturer's safety
data sheets.

16 DSS-G21