BLADDER ACCUMULATORS SERVI FLUID POWER, INC.
Transcription
BLADDER ACCUMULATORS SERVI FLUID POWER, INC.
BLADDER ACCUMULATORS SERVI FLUID POWER, INC. OVERVIEW The Servi Group The Servi Group offers over 80 years of experience with Power and Motion Control in the global hydraulic market. The Servi Group is recognized as the Norwegian market leader for hydraulic solutions and systems in the offshore and marine industry, developing and producing custom hydraulic systems, cylinders, valves and accumulators. The Servi Group has been providing both bladder and piston accumulators for more than 50 years. Servi Fluid Power Inc. Servi Fluid Power, Inc., a division of the Servi Group, was formed in 2014 to provide the design, assembly and service of bladder accumulators including high and low pressure customized designs to suite variety of applications. Additionally Servi Fluid Power, Inc. manufactures highly engineered solutions for custom Piston Accumulators based out of our facility in Rissa, Norway. Markets include but not limited to: • Oil/Gas • Marine • Industrial • Mobile • Renewable Applications include but not limited to: • Energy storage • Shock Absorption • Pulsation Dampening • Thermal Expansion • Suction Stabilizing Servi Fluid Power Inc. product range Expertise Executives from the accumulator market have combined their efforts with Servi Group’s overall hydraulic knowledge, technical expertise and history of providing a quality service to form Servi Fluid Power, Inc. Servi Fluid Power, Inc. has amassed global industry experts with experience exceeding 25 years. The team consist of leading talent to include Assembly Technicians, Manufacturing Management, Quality Control, HSE, Supply Chain, Engineering, Commercial, Finance, and Executive Management. All team members have been specifically recruited based on their knowledge, respect and proven history in the business. Core Values Integrity – Continue to build respectful relationships that cultivate trust and reliance on service and quality. Custom product engineering solutions Reliability – Competitive advantage to our customer through unparalleled quality and delivery performance. Operational Excellence – Build best in class manufacturing, creating a continued pursuit to improvement. Innovation – Leading edge engineering support and collaboration with both the customer and supply partners. Mission Statement To provide value added solutions reducing costs, ensuring safety and improving performance for all integrated hydraulic systems. To create the standard in quality, process and innovation while remaining loyal to the commitment of service to the customer. 2 Optimized production HYDRAULIC ACCUMULATORS Accumulator Introduction Design Features The hydro-pneumatic accumulator stores energy in the form of pressurized hydraulic fluid and releases to the hydraulic system when demanded either immediately or intermittently. A separator between the compressible dry inert gas such as nitrogen and incompressible hydraulic fluid allows the stored fluid to be discharged per the system requirements. The most common types of accumulators are Bladder type which uses bladder as a separator to store gas, Piston type which uses piston as a separator between the gas and fluid chamber and Diaphragm type which uses a diaphragm as a gas separator from hydraulic fluid. All three types of accumulators have their own advantages and limitations which should be considered when selecting for an application. Accumulator Shell A bladder accumulator shell is forged from a chrome molybdenum high strength carbon steel material that is seamless with hemi head ends. They are designed and manufactured to ASME code material and design specifications. The pressure rating is based on a 4:1 safety factor exceeding the requirements of ASME code. Bladder The bladders are offered in several different material choices and operating temperatures to be compatible with various fluids and severe applications. Refer to the table on page 5 for the common choices for the bladders. Bladder Accumulator Benefits Industries and Applications Improve system performance and efficiency - Reduce operation and maintenance costs - Ensure fail-safe conditions - Increase uptime and prolong system life expectancy - Quick response time - Contamination tolerant - Safety – Cannot be disassembled under pressure - Lighter weight - Recommended for water based or low lubricity fluids - Field repairable - Parts interchangeable with major brands. Industries Applications Die Casting Machinery High Pressure energy storage for rapid flow Plastic Machinery For quick response Machine tools Maintains pressure, reduces pump size Automotive Braking, Suspension, Transmission Systems Chemical Industry Reduce pump pulsations Oil & Gas/Offshore Emergency valve closing Agriculture Machinery Suspension systems Wind Energy Pitch Control and Braking Accumulator Operating Principle - Typical Operation The rubber bladder inside the pressure vessel is pre-charged with nitrogen gas as per the system requirements. Stage 1 Accumulator is pre-charged with nitrogen gas based on the system requirements. During this stage, the hydraulic system pressure is lower than the pre-charge pressure. Stage 2 The Hydraulic system is pressurized causing the fluid to enter the accumulator when the fluid pressure exceeds pre-charge pressure (Charging cycle). Stage 3 The system pressure reaches to the maximum limit filling the accumulator to its maximum capacity. This is a fully charged state. When system pressure falls, the compressed nitrogen gas forces the fluid from the accumulator into the system until it reaches system minimum pressure (Discharge cycle). A typical accumulator function cycle is between stage 2 and stage 3 during operation. Stage 1 Stage 2 Stage 3 3 MODEL CODE CHART Standard Product Model Code Chart MODEL CODE BA 01 - 03 - NC - N - 0 - 1 - A - 00 - 00 Accumulator Model Code Description BA Bladder Accumulator Standard BT Bladder Accumulator Top Repairable HF High Flow Bottom Repairable HT High Flow Top Repairable GB Gas Bottle External Coating (only when requested) Code Description BLANK Primer only 01 Shell external coating (See Note 2) Internal Coating (only when requested) Code Description BLANK No Internal coating Nominal Capacity 01 Shell Internal Coating (See Note 2) Code Description Certifications 1P 1 Pint 01 0.25 Gal 04 1 Gal A ASME 10 2.5 Gal B ASME + ABS 20 5 Gal C ASME + CRN 37 10 Gal D ASME+DNV 42 11 Gal E ASME+ABS+DNV 57 15 Gal F CE G ASME+CE H ASME+CE+ABS+DNV J ASME+CE+CRN+AS1210 K ASME + AS1210 Pressure Rating Code Description 02 2000 psi 03 3000 psi Code Description Material Option 04 4000 psi 05 5000 psi 60 6000 psi 1 Carbon Steel Shell & Carbon Steel Trim 06 6500 psi 2 Carbon Steel Shell & Stainless Steel Trim 10 10000 psi 3 Stainless Steel Shell & Stainless Steel Trim 4 Nickel Plated Shell & Stainless Steel Trim Code Description Fluid Port Connection Service Code Description NC 3/4" NPT Code Description ND 1" NPT O NE 1-1/4" NPT W Water Service (Nickel Plated Shell) NF 1-1/2" NPT F Flushing per customer specification NG 2" NPT T Unit testing per customer requirement SH -12 SAE (1-1/16"-12 threads) SJ -16 SAE (1-5/16"-12 threads) SK -20 SAE (1-5/8"-12 threads) Oil Service Bladder Material Code Description SL -24 SAE (1-7/8"-12 threads) N Nitrile BC G3/4" BSP C Cold Weather Nitrile BD G1-1/4" BSP T Extreme Cold Weather Nitrile BH G2"BSP F Flouroelastomer (FKM) FA 2" Code 61 B Butyl FB 1-1/2" Code 62 E EPR FC 1-1/4" CODE 61 H Hydrin Notes: 1. Model Code combinations contain non standard options. Not all combinations are available, Please consult factory for information and availability. 2. The code designator for external and internal coding is a sequential number specific to each customer and paint system. Please consult factory for additional details. 4 BLADDER DETAILS Bladder Compounds and Operating Temperatures Rubber Compound Operating Temp Range General Fluid Compatibility Standard Nitrile (NBR) -10°F thru 220°F -23°C thru 104°C Compatible with most standard petroleum based hydraulic oils. Low Temperature Nitrile -50°F thru 200°F -45°C thru 93°C Compatible with most standard petroleum based hydraulic oils. Extreme Low Temp Nitrile -65°F thru 200°F -54°C thru 93°C Compatible with most standard petroleum based hydraulic oils. Ethylene Propylene (EPR) -55°F thru 330°F -48°C thru 166°C Compatible with most phosphate esters Butyl (IIR) -45°F thru 200°F -42°C thru 93°C Compatible with most phosphate esters Fluoroelastomer (FKM) 0°F thru 350°F -17°C thru 176°C Compatible with most petroleum based fluids at high temperatures and some special fluids Epichlorohydrin (ECO) -40°F thru 275°F -40°C thru 135°C Compatible with most standard petroleum based hydraulic oils. * Information is for reference purpose only. Consult factory for fluid compatibility or refer to fluid manufacturers recommendations. Bladder Design Criteria Chemical Compatibility: ASTM D-471 ISO-1817 Gas Permeability: ASTM 1434-82 (2003) PROCEDURE V ISO-2782-1995 Operating Temperature Range: ASTM D-1053-92a(07) ISO-812 Mechanical/Physical Properties: ASTM D-412, D-624 ISO-37, ISO34-2, ISO-4649. • Tested and qualified for severe applications • Superior permeation resistance of Nitrogen gas • Optimized compound mix for improved physical properties • Excellent resistance to high and low temperatures • Available in several compounds to suit variety of fluids and operating temperatures • Excellent shelf life • Special compounds and sizes available to suite various applications 5 BLADDER ACCUMULATORS 3000 PSI Series * * * * 1 Gal. FC 1-1/4” Code 61 BE 1-1/4” BSP 1 Gal. Gal. FC 1-1/4” Code BE 1-1/4” BSP 2.5-15 FA 2” Code 6161 BH 2”BSP 2.5-15 FA 2” Code 6162 BH 2”BSP 2.5-15 Gal. Gal. FB 1-1/2” Code BC 3/4” BSP 2.5-15 Gal. FB 1-1/2” Code 62 BC 3/4” BSP Refer to Model Code Chart on page 4 for Part Numbers and Ordering Refer Refer to to Model Model Code Code Chart Chart on on page page 4 4 for for Part Part Numbers Numbers and and Ordering Ordering 6 BLADDER ACCUMULATORS 5000 PSI Series * * * Refer to Model Code Chart on page 4 for Part Numbers and Ordering 7 HIGH FLOW ACCUMULATORS High Flow 3000 PSI Series High Flow Bottom Repairable 3000 psi (207 Bar) Size Gas Volume Dimensions In. (mm) Port Thread [E] Weight Gal. Liters Cu.In (Liters) A B C D SAE NPT Lbs (Kg) 560 21 3.5 9.06 3.0 80 2.5 10 4- 1/4"-8UN 4"-8 (9.2) (534) (89) (230) (76) (36.5) 1126 33.5 3.5 9.06 3.0 120 5 20 4"-8 4- 1/4"-8UN (18.5) (851) (89) (230) (76) (54.5) 2110 54 3.5 9.06 3.0 220 10 37 4- 1/4"-8UN 4"-8 (34.6) (1372) (89) (230) (76) (100) 2390 59.5 3.5 9.06 3.0 240 High 11 Flow 42Bottom Repairable 3000 psi (207 Bar) 4- 1/4"-8UN 4"-8 (39.3) (1511) (89) (230) (76) (109) Size Gas Volume Dimensions In. (mm) Port Thread [E] Weight 3300 77.5 3.5 9.06 3.0 305 Gal. Liters Cu.In (Liters) A B C D SAE NPT Lbs (Kg) 15 57 4"-8 4- 1/4"-8UN (54.3) (1969) (89) (230) (76) (139) 560 21 3.5 9.06 3.0 80 2.5 10 4- 1/4"-8UN 4"-8 (9.2) (534) (89) (230) (76) (36.5) 1126 33.5 3.5 9.06 3.0 120 5 20 4"-8 4- 1/4"-8UN (18.5) (851) (89) (230) (76) (54.5) High Flow Top Repairable 3000 Bar) 3.0 2110 54 psi 3.5(207 9.06 220 10 37 4- 1/4"-8UN 4"-8 (34.6) (89) (230) (76) (100) Size Gas Volume (1372) Dimensions In. (mm) Fluid Port Thread Weight 2390 3.5 9.06 3.0 240 Gal. Liters Cu.In (Liters) 59.5 A B C D SAE NPT Lbs (Kg) 11 42 4- 1/4"-8UN 4"-8 540 20.5 (89) 3.5 (230) 9.06 (76) 3.0 90 (39.3) (1511) (109) 2.5 10 4- 1/4"-8UN 4"-8 (8.8) (521) (41) 3300 77.5 (89) 3.5 (230) 9.06 (76) 3.0 305 15 57 4"-8 4- 1/4"-8UN 1106 33 (89) 3.5 (230) 9.06 (76) 3.0 125 (54.3) (1969) (139) 5 20 4- 1/4"-8UN 4"-8 (18.2) (838) (89) (230) (76) (57) 2090 53.5 3.5 9.06 3.0 225 10 37 4- 1/4"-8UN 4"-8 (34.4) (1359) (89) (230) (76) (102) 2370 59 3.5 9.06 3.0 245 High 11 Flow 42Top Repairable 3000 psi (207 Bar) 4- 1/4"-8UN 4"-8 (39) (1499) (89) (230) (76) (111) Size Gas Volume Dimensions In. (mm) Fluid Port Thread Weight 3280 77 3.5 9.06 3.0 310 Gal. A B C D SAE NPT 15 Liters 57 Cu.In (Liters) 4- 1/4"-8UN 4"-8 Lbs (Kg) (53.9) (1956) (89) (230) (76) (141) 540 20.5 3.5 9.06 3.0 90 2.5 10 4- 1/4"-8UN 4"-8 (8.8) (521) (89) (230) (76) (41) 1106 33 3.5 9.06 3.0 125 5 to20 4- 1/4"-8UN 4"-8 Refer Model Code Chart on Page 2 for Part Numbers and Ordering. (18.2) (838) (89) (230) (76) (57) 2090 53.5 3.5 9.06 3.0 225 10 rates 37of up to 600 GPM 4- 1/4"-8UN 4"-8 Flow (34.4) (1359) (89) (230) (76) (102) Fluid port connections are Male SAE or NPT threads 2370 59 3.5 9.06 3.0 245 11 42 4- 1/4"-8UN 4"-8 Optional flange connection available with the SAE port option (39) (1499) (89) (230) (76) (111) 3280 77 3.5 9.06 3.0 310 15 57 4- 1/4"-8UN 4"-8 (53.9) (1956) (89) (230) (76) (141) Refer to Model Code Chart on page 4 for Part Numbers and Ordering Refer to Model Code Chart on Page 2 for Part Numbers and Ordering. Flow rates of up to 600 GPM Fluid port connections are Male SAE or NPT threads Optional flange connection available with the SAE port option 8 GAS BOTTLES Gas Bottle Series * * * * * * Refer to Model Code Chart on page 4 for Part Numbers and Ordering 9 OTHER BLADDER ACCUMULATORS Stainless Steel 2000 PSI Series High Pressure 10,000 PSI Series Refer to Model Code Chart on page 4 for Part Numbers and Ordering 10 CERTIFICATIONS Servi Fluid Power, Inc. shall have quantifiable goals for their quality work and delivery precision, and strive for continuous improvement. All our companies shall have clearly documented procedures for their activities, and work continuously at making the procedures better and more efficient. Through information and training, we shall ensure that all employees have a high level of quality consciousness. Servi Fluid Power, Inc. is certified according to the Quality Management System ISO 9001:2008. • • • • • • • • • CE/PED – Europe CRN – All provinces in Canada AS1210 – Australia ASME – Americas DNV – Type Approval available ABS – Product Design Approval available NR13 – Brazil TR CU – Russia Consult factory for any other certifications. 11 CHARGING & MAINTENANCE Maintenance Tools Charging Kits Repair & Maintenance Tools RT-01 Bladder Pull Rod 1PT - 2.5 Gal RT-02 5 Gal (2 Rods) For optimum and reliable operation of accumulators, it is important to fill and maintain the correct nitrogen pre-charge pressure. We recommend checking pre-charge pressure regularly. Charging & gauging kits are designed to fit on a commercially available nitrogen bottles. Charging instructions are provided with charging kit for safe operation. Charging & Gauging Unit P/N Description RT-03 10 & 11 Gal (3 Rods) RT-04 15 Gal (4 Rods) RT-05 Spanner Wrench RT-06 Valve Core Repair Tool Part # Pre-charge Gas Description CKT-0030 Charging & Gauging Assy - 3000 PSI CKT-0050 Charging & Gauging Assy - 5000 PSI CKT-T-0030 C&G Assy kit - Top Rep. - 3000 PSI CKM-0030 C&G Manifold Assy - 3000 PSI CKM-0050 C&G Manifold Assy - 5000 PSI Parts List Although any inert gas can be used to pre-charge the accumulator, we recommend to use high purity dry nitrogen gas only for pre-charge. Never use shop air or oxygen to avoid any risk of explosion. Accumulators are normally shipped with pre-charge pressure of 25 psi for shipping purpose only unless otherwise specified by the customer differently. Accumulator must be pre-charged to the required pressure prior to operation to avoid the risk of bladder failure when commissioning. Our general recommendations for nitrogen pre-charge varies by application and are as follows. Energy Storage – 90% of the minimum system operating pressure. Shock Absorption – 60%-75% of the normal working pressure. Pulsation Dampening – 60%-80% of the normal working pressure. The above recommended pressures must be adjusted taking operating temperatures into consideration. Pre-charge pressure must be checked during first week in operation. Subsequent maintenance should be done 3 to 6 months depending on the severity of the application. High cycling and high temperature applications require maintenance every 3 months. 2 Item # Part # Description 1 CK-0030 Gauge - 3000 PSI 2 CK-001 Storage Box 3 CK-002 Manifold 4 CK-004 Swivel Connector 5 CK-005 Air Chuck 6 CK-006 Hose Assy - 3000 PSI 7 CK-010 Tank Valve 8 CK-011 Bleeder Valve 9 CK-013 Valve Extension 10 CK-009 Gland Nipple 11 CK-008 Gland Nut 5 1 3 4 10 7 11 8 6 9 Storage box included with Charging Kit 12 Valve Extension (Required for charging Top Repairable units) included with CKT-T-0030 Kit MOUNTING & INSTALLATION Recommended Installation Recommended bladder accumulator installation is in vertical position with fluid port at the bottom for optimum performance. Bladder accumulator mounted horizontally will reduce the performance due to trapped fluid and service life of the bladder reduced due to excessive wear when rubbing against the shell. Accumulators subjected to external forces may also have detrimental effect on performance and life expectancy. We also recommend the use of our mounting clamps and brackets to ensure rigid and safe installation of the accumulator in the hydraulic system. Mounting Accessories We strongly recommend using our mounting accessories to install accumulators to ensure safe and secure installation. They are designed to carry the weight of the accumulator as well as counteract any forces or vibrations transmitted from the hydraulic lines. Recommended installation is vertical with Hydraulic port down. Design Features Material used for clamps and brackets are typically hot or cold rolled galvanized steel that offer exceptional strength and durability. A rubber cushioning sleeve on the clamp and a rubber grommet on the bracket provide isolation from system vibrations Clamps for accumulators and gas bottles Gas Valve Charging Connection (0.305-32 UNS 8V1 Threads) Gauge Accumulator Mounting Clamps Part # Description A B C D E F G CL01-1 Clamp 1 Quart 5.26 3.90 6.88 2.83 0.5 4.78 - CL04-1 Clamp 1 Gallon 7.58 6.25 9.06 3.96 0.5 7.0 - CL10-03-1 Clamp 2.5-15G 3K 10.00 8.50 10.00 5.19 0.62 12.5 9.00 CL10-05-1 Clamp 2.5-15G 5K 10.55 8.50 10.43 5.35 059 12 9.53 Permanent Gauge Block Kits Hoist Assembly Permanent Gauge Block Kits Part # Description PGBK-03-1LM3K TPGBK-03-1LM3K PGBK-05-1-LM3K A B Bottom Repairable 3.55 3000 PSI Kit 2.75 Top Repairable 3000 PSI Kit 4.55 5.30 Top/Bot Repairable 3.78 3.34 C 4.4 4.4 4.4 5000 PSI Kit D E 3/8-24 1/4 UNF NPT 3/8-24 1/4 UNF NPT 1/2-20 1/4 UNF NPT Hoist Assembly for Lifting Part # Accumulator Base Brackets Part# Description A B C D E F G H I HA-PC04-B1 Description A(in) B(in) C Max. Load 1-15 Gal 3k Hoist Assy 5.7 2.3 7/8”-14UN 1000 lbs BK-03-1 2.5-15G Saddle 10.25 3000 PSI 8.87 3.87 4.84 6.68 7.87 1.34 0.67 1.56 HA-PCT10-B1 2.5-15 Gal 5k Top Re- 7.5 pairable Hoist Assy 2.3 7/8”-14UN 1000 lbs BK-05-1 2.5-15G Saddle 10.25 5000 PSI 9.00 3.90 5.1 6.68 7.80 1.00 0.75 1.70 HA-PC10-C1 2.5-15 Gal 5k Bottom 6.7 Repairable Hoist Assy 2.5 2”-12UN * We recommend to install 2 clamps for 10 Gal and above size accumulators for secure installation 1000 lbs 13 ASSEMBLY Optimized Assembly Process on Conveyor System We supply to the line and maintain continuous flow where operator works with designated work zone. This is a break away from the current industry practice of bench building or line building with multiple operators either side of the line. By having synchronized line feed we can outperform the competition in term of efficiency and delivery, whilst maintaining a quality standard that meets the customer’s need and expectations. From our factory in Katy, Texas, we assemble and ship wide range of bladder accumulators not only for the American market but also globally with all the applicable approvals and certifications. We also offer custom engineered products to suit various applications and industries. 14 SERVI GROUP PRODUCT PORTFOLIO Over 50 years in piston accumulators Servi is Norway’s largest manufacturer of piston accumulators. Servi manufactures a standard range of piston accumulators in both carbon and stainless steel suitable for Offshore & Marine, Power-Gen, Mobile and Industrial markets. Design pressures range from 3000 to 5000 psi with capacities ranging from 0.05 Gal to 130 Gal. Standard approval are CE as per PED 97/23/EC. These accumulators are customized to suite applications such as: • Dampeners • Heave compensators • Press, Crane and Winches • Gates, Hatches and Covers on Furnaces • Tensioning systems • Conveyor systems Special Accumulators Servi manufactures special piston and bladder accumulators with custom options in low and high pressure applications. • Piston Accumulators with electrical limit switches • Piston Accumulators with position indicators • High pressure bladder accumulators Servi Group Products & Services Since 1912, Servi Group has been a key player within Power and Motion Control, with particular emphasis on the marine and offshore industry. In addition to being the largest manufacturer of Piston Accumulators in Norway, Servi offers many unique high quality performance products and services. • • • • • • Valve blocks Cylinders Comprehensive range of repairs and maintenance Hydraulic testing Hydraulic repairs Amplifiers Cyclone Tank Servi has developed a unique reservoir for hydraulic systems based on cyclone principle. The technology uses the difference in density between oil and air. Rotation accelerates the deaeration of oil thereby reducing the reservoir volume by up to 90% compared to a traditional reservoir. Some of the benefits from this include: • • • • • • Drastic reduction of reservoir size and oil volume Lower weight More effective deaeration of oil Extended oil life Lower maintenance cost Reduce environment impact Standard Piston Accumulators Special Accumulators with custom options in low and high pressure applications Cyclone Element Product development and production at Servi cylinder services facility in Rissa, Norway 15 Servi Fluid Power Inc. Katy, Texas SERVI FLUID POWER Inc. 22240 Merchants Way, Suite 100 Katy, TX 77449 Tel: +1(281)347-8080 E-mail: [email protected] www.servi-inc.com SERVI GROUP Rasmus Solbergs vei 1 Postboks 3230 1402 Ski Servi Hydranor AS T + 47 64 97 97 97 Reg. no.: [email protected] NO 936 370 446 MVA Rasmus Solbergs vei 1 Bergmannsveien 241 Stensarmen 4 Skibasen 330 Postboks 3230 3615 Kongsberg 3112 Tonsberg 4636 Kristiansand 1402 Ski T + 47 48 06 56 56 T + 47 90 13 43 43 T + 47 38 10 22 90 T + 47 64 97 97 97 [email protected] [email protected] [email protected] [email protected] Midtunhela 20 Lade Allé 9 Bedriftsveien 15 5224 Nesttun Postboks 5665 Sluppen 4313 Sandnes T = 47 55 10 82 20 7484 Trondheim T + 47 51 97 28 00 [email protected] T + 47 73 80 10 00 [email protected] [email protected] Servi Ulsteinvik AS Servi Cylinderservice AS Brendehaugen 24 Kvithyll 6065 Ulsteinvik 7100 Rissa Norway Norway T +47 70 01 85 80 T +47 73 85 05 00 [email protected] [email protected] Reg. no.: Reg. no.: NO 979 185 901 MVA NO 984 846 436 MVA Copyright © 2015 Servi Group. All rights reserved. Member of Servi Group LT - 05, Q2 - 2015
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