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API Plan 53-Accumulator Bladder Charging

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safe procedure for Accumulator bladder charging by nitrogen in Plan 53
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    Fawcett Christie Hydraulics (I) Pvt. Limited No. 21/C, KIADB 1 st  Phase, Bangalore - Mysore Highway, Kumbalagodu, BANGALORE – 560 074. Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in   Precharging of Accumulators … 1/3 IMPORTANT  Use nitrogen gas only. All accumulators are supplied Unprecharged unless specifically requested at the time of ordering. Prior to installation in the hydraulic circuit all accumulators must be precharged with Nitrogen. Check model number of accumulator on label for working pressure. Always use the nitrogen pressure regulator valve when accumulator shell pressure rating is lower than gas pressure in nitrogen cylinder. The commercial nitrogen cylinders available with 130-140bar. Precharge vary with operating conditions check with Fawcett Christie if no precharge has been Previously recommended, for a guide the following values can be used. Storage application: 90% of minimum allowable system pressure. Pulsation application 70% of mean pumping pressure. Shock application: 90% of flow pressure at accumulator position. N.B. Precharge must never be below 20% of maximum system pressure. Ensure bladder has been lubricated with system fluid before commencing Precharging PRECHARGING PROCEDURE  The following procedures should be adopted for safe Precharging of accumulators. All Precharging Equipment specified is detailed    For accumulators having a shell working pressure less than the nitrogen source refer to fig. 2 .    For accumulators having a shell working Pressure equal to or greater than the nitrogen source refer to fig . 3  see note 4.      For Accumulator fitted with permanent charging set refer to fig 4.      For transfer barrier accumulators refer to Fig. 5 .    Fawcett Christie Hydraulics (I) Pvt. Limited No. 21/C, KIADB 1 st  Phase, Bangalore - Mysore Highway, Kumbalagodu, BANGALORE – 560 074. Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in   Precharging of Accumulators … 2/3 Procedure I  - using a Nitrogen pressure regulator valve PRV) fig. 2.   A Remove protective cap( 1 ) fitted and the sealing cap ( 2 ).   B Attach NPRV ( 3 ) to nitrogen cylinder ( 4 ).   C Attach charging set ( 5 ) to accumulator gas Valve assembly ( 6 ) and connect charging hose ( 7 ) between NPRV ( 3 ) and charging set connection   D Back off handle ( 8 ) anti clockwise until loose, check gas bleed valve (9) on charging set is closed and screw hand wheal ( 10 ) clockwise to open gas valve.   E Open nitrogen cylinder valve by turning key ( 11 ). cylinder pressure will register on right hand gauge ( 12 ). This pressure should be checked against the required precharge pressure. F Turn handle( 8 ) clockwise until outlet pressure on left hand gauge( 13 ) registers 10% higher than the required precharge pressure. When pressure on the charging set and outlet gauges are equal, close Nitrogen Cylinder Valve. G Turn hand wheel ( 10 ) anti-clockwise to seal gas valve. H Crack bleed valve( 9 ) to exhaust gas from charging hose and remove hose from charging set and replace hose connection Sealing cap.   I Close bleed valve, turn hand wheal ( 10 ) clockwise to open gas valve and crack bleed valve ( 9 ) to vent down to required precharge pressure. Close bleed valve   J Turn hand wheal ( 10 ) anti-clock wise to reseal gas valve, crack bleed valve and remove charging set from the accumulator   K Test accumulator gas valve for leaks using a leak detection spray or soapy water solution.   L Replace, sealing cap( 2 )and tighten with pliers and protective cap ( 1 ) if fitted   Procedure II Nitrogen pressure regulator Valve not used. Fig. 2,3,4 and 5. M Remove protection cap( 1 ) if fitted and the sealing cap ( 2 ) and attach charging set to accumulator gas valve assembly. N Connect charging hose ( 7 ) to nitrogen cylinder ( 4 ) using the appropriate adaptor and attach the free end to the charging set. O Turn hand wheel ( 10 ) clockwise to open gas valve and slowly open nitrogen. P Allow pressure on the gauge (14)  to read slightly in excess of required precharge then close nitrogen cylinder valve. To complete procedure follow steps g  to h  above.    Fawcett Christie Hydraulics (I) Pvt. Limited No. 21/C, KIADB 1 st  Phase, Bangalore - Mysore Highway, Kumbalagodu, BANGALORE – 560 074. Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in   Precharging of Accumulators … 3/3 Procedure III Permanent charging set fitted Fig,4 & 5 q Follow above steps, adopting either procedure I  or II  depending on accumulator working pressure, connecting the charging set to the gas value set as shown in fig.4 & fig.5. Procedure IV Precharging of Diaphragm Accumulator (Fig.6) R Remove protection cap (1) if fitted attach the charging set to the accumulator on the M28xl.5 Gas valve stem (2). S Connect charging hose(7) to nitrogen cylinder (4) using the appropriate adaptor and attached the free end to the charging set. T Turn Hand wheel (10) anti-clockwise to open the gas valve. U Allow pressure on the gauge (14) to read slightly in excess of required Precharge. Then close nitrogen cylinder valve. V Turn hand wheel (10) clockwise to seal gas valve. W Crack bleed valve (9) to exhaust gas From charging hose and remove hose from charging set and replace hose connection sealing cap. X set the required precharge by releasing the gas operating hand wheel and Bleed Valve. Y Tighten the accumulator Allen bolt (15) test for leakage using spray soapy water solution    Fawcett Christie Hydraulics (I) Pvt. Limited No. 21/C, KIADB 1 st  Phase, Bangalore - Mysore Highway, Kumbalagodu, BANGALORE – 560 074. Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in   Installation of Accumulators Inspection of Accumulator  : All Fawcett Christie accumulators are thoroughly inspected prior to dispatch from our factory and are ready for installation following pre charging. After unpacking the accumulators, inspection of the accumulators for possible damage during transit. Check the, all nuts, screws, locking rings, bleed screws, adaptors and fittings, for tightness. check that the maximum pressure of the accumulator is equal to or greater than the maximum pressure of the system.(see interpretation of markings). 2. Installation recommendations . All accumulators are supplied un-pre charged from the factory unless requested. Prior to applying hydraulic pressure to the system all accumulators must be pre charged with nitrogen. It will be necessary to check the gas pre charge pressure at regular intervals. The provision of a safety block fitted between the accumulator and fluid pressure line to enable isolation of hydraulic system pressure. The location of the gas-charging valve with regard to the potential for accidental damage and safe discharge of high-pressure gas. The provision of a warning label (in addition to that provided on the accumulator nameplate) stating PRECHARGED WITH N2 GAS AT ....BAR . It is necessary to ensure that the accumulator is protected from overpressurisation. General protection is usually provided by the hydraulic system relief valve, which should be set at no higher than 10% above the maximum working pressure (MWP) of the accumulator. Specific protection for the accumulator can be provided in the following ways: A hydraulic relief valve located in a safety block will prevent both liquid and gas side overpressurisation. A fusible plug will relive gas side pressure in the event of a fire. And a burst disc will relieve gas side overpressurisation. On storage applications a check valve fitted between pump and accumulator will ensure non-reversal of the pump. For maximum efficiency and service life, accumulators should be mounted vertically where possible, fluid port facing down. For fluid port and gas connection threads see our catalogue. If it is necessary to adapt to another size, special adaptors are available. A range of clamps, support brackets and other accessories are available to assist in installation. Their use is strongly recommended.  
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