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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.


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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.


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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


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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


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07478981841


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


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


166.230225.570322.720492.720831.1001.609.000

w/o limitation


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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


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


118.140164.510244.560395.230732.5001.664.000

w/o limitation


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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


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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