Repair and overhaul of pressure accumulator systems
HANSA-FLEX Industrial Service supports you with all servicing and maintenance work on your pressure accumulator systems, including nitrogen filling or their replacement.
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PRESSURE ACCUMULATOR INSPECTIONS ARE OBLIGATORY
Pressure accumulators are among the systems that need to be monitored by law and must therefore be checked regularly by trained specialist personnel who are officially authorised persons in accordance with the German Industrial Safety Act (BetrSichV). In addition, a safety assessment (risk assessment) must be prepared to ensure the safe operation of machines and systems with inbuilt hydraulic accumulators.
Inspection of hydraulic accumulators by officially authorised persons
At HANSA-FLEX, a large number of employees throughout Germany are qualified as competent persons for pressure equipment. As fluid experts, they also have extensive experience with pressure accumulators, provide expert advice on all questions and are always ready to help you. HANSA-FLEX offers its customers the following services:
- Performance of recurring inspections
- Support in the preparation of risk assessments
- Documentation of inspection results in accordance with BetrSichV
HANSA-FLEX SERVICES OFFER ALL THESE ADVANTAGES
With HANSA-FLEX, the leading experts in fluid technology, you always have an experienced partner in pressure equipment technology at your side.
Qualified specialist personnel
Inspections performed by officially authorised persons (TRBS 1203 No. 3.2 and No. 2).
No compromise on safety
Ensure compliance with all the requirements of the German Industrial Safety Act.
Comprehensive support
We support you in the preparation of risk assessments and your inspection and testing plans.
CLASSIFICATION OF PRESSURE ACCUMULATORS
The scope of the inspections depends on the category of the pressure accumulator. Hydraulic accumulators are divided into systems that need to be monitored and systems that do not need to be monitored in accordance with the European Pressure Equipment Dir
Large pressure accumulators with an operating pressure of more than 1 bar
All hydro storage tanks with a gas volume of more than 10 l are considered to be systems requiring monitoring and are subject to special inspection obligations and regular inspections in accordance with the German Ordinance on Industrial Safety and Health (BetrSichV) during commissioning. Acceptance after installation as well as all periodic tests on these pressure accumulators may only be carried out by experts from an approved monitoring body (ZÜS) or a company commissioned by the latter, such as TÜV or DEKRA. The deadlines for the periodic inspections are based on the safety assessment and must be determined no later than 6 months after commissioning and checked by a ZÜS.
Medium-pressure accumulators with an operating pressure of not more than 1 bar
Hydropneumatic pressure accumulators with a gas volume between 1 and 10 l must be tested both before commissioning and at recurring intervals. All tests must be carried out by a qualified person for pressure hazards (TRBS 1203 No. 3.2).The operator independently determines the test periods on the basis of the information provided by the manufacturer, the mode of operation and his own experience. The test intervals specified in the BetrSichV are for guidance only.
Small pressure accumulators with an operating pressure of not more than 0.5 bar
Pressure accumulators with a gas volume of between 0.1 l and 1 l are classified as pressure systems that do not require monitoring and are considered work equipment within the meaning of the BetrSichV.Testing prior to commissioning is not mandatory, but the operator must nevertheless determine appropriate protective measures in accordance with the risk assessment drawn up. This also includes the performance of a periodic inspection in accordance with §10 of the BetrSichV by a qualified person for hazards caused by pressure in accordance with TRBS 1203 No. 2.
PROCESS AND SCOPE OF PRESSURE ACCUMULATOR INSPECTIONS
Inspection before bringing into first use
Before commissioning a pressure accumulator, in addition to the technical functionality, it is checked whether a CE marking, operating instructions, the identification number of the notified body and the necessary safety equipment are available. Depending on the category of the accumulator, the test is carried out from different bodies:
- More than 10 l gas volume: Approved monitoring body (ZÜS)
- Up to 10 l gas volume: Qualified person for hazards due to pressure according to TRBS 1203 No. 3.2
- Less than 1 l gas volume: Qualified person according to TRBS 1203 No. 2
Recurring inspections
As part of the periodic inspections, it is ensured that the CE marking and operating instructions are available and that the equipment with safety function is still present, functional and correctly adjusted. In addition, it is checked whether the prerequisites for the next test interval are still correct. You should definitely have the following documents ready:
- Instruction manual and risk assessment
- All documents of the manufacturer of the hydraulic accumulator
- The operational documents of the commissioning test
UNSCHEDULED INSPECTIONS IN THE COURSE OF SERVICING AND MAINTENANCE
Changing the operating pressure
Changing the operating pressure of an accumulator always affects the safety of the entire system or machine. Therefore, if the operating pressure is adjusted, a new test is required before commissioning. Depending on the category of the hydraulic accumulator, this must be carried out by a competent person or the authorised inspection body (ZÜS).
Replacing identical accumulators
When replacing a hydraulic accumulator in a machine or system with an identical accumulator, no new acceptance test by an authorised inspection body (ZÜS) or a competent person is required. The period up to the first periodic inspection runs from the time the new hydraulic accumulator is commissioned in accordance with the inspection intervals already specified.
New installation location
If the installation location of the accumulator is changed, for example when it is installed in another machine, a pre- commissioning test is only not required under certain conditions:
- Pre-commissioning test already carried out elsewhere
- No new operating mode
- Unchanged connection conditions and equipment
- No special requirements for installation site
Maintenance work
After maintenance work such as replacing bladders, diaphragms or seals, the hydraulic accumulator must be inspected periodically by the relevant specialised personnel. This regulation applies to all pressurised devices with a gas volume of 1 l or more.
Storage of hydraulic accumulators
Damage such as corrosion to the safety equipment or signs of ageing of the elastomer can occur during storage of pressurised accumulators. For this reason, the entire hydraulic accumulator should be inspected by a specialist before installation. It is also important to know that the inspection period is not extended during storage.
ALL-ROUND CAREFREE SERVICE FROM THE FLUID SPECIALISTS
HANSA-FLEX is your competent partner for all the tasks required for the installation and operation of pressure accumulators.
- Advice on the selection and design of pressure accumulators
- Sales of pressure accumulators, accessories and repair kits
- Installation of pressure accumulators
- Maintenance and repair by officially authorised persons
- Training and seminars on the servicing and operation of pressure accumulators
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