Sizing Accumulators
Basic Accumulator Terms
p0 = gas precharge pressure
p1 = minimum working pressure
p2 = maximum working pressure
p0 @T0 = gas precharge pressure at precharge ambient temperature
p0 @T1 = gas precharge pressure at minimum ambient temperature
p0 @T2 = gas precharge pressure at maximum ambient temperature
Accumulator Operational Sequence Steps
Bladder
1 The bladder accumulator is precharged with
nitrogen to system design specified precharge
pressure prior to accumulator installation.
The expanded, pressurized bladder
causes the fluid port poppet to close,
preventing the bladder from extruding
into the fluid port.
No fluid is inside the accumulator at this
step until the accumulator is installed
in the hydraulic system and the system
pressure becomes greater than the
precharge pressure, P0.
Once the system working fluid pressure
becomes greater than P0, the poppet
will open and the bladder will begin to
compress.
2 The accumulator is installed in the hydraulic
system and the fluid is increased to the
maximum working system pressure, P2. This is
often called charging the accumulator.
At P2, the gas volume in the bladder
accumulator is V2.
At this step the maximum amount of fluid
possible for a particular system pressure
range is inside the accumulator and the
fluid is compressing the bladder and
nitrogen gas to smallest gas volume.
3 During operation, the minimum working
system pressure, P1, is reached and the
gas volume is now V1. This is often called
discharging the accumulator.
V1 is the maximum gas volume during
hydraulic system operation and correlates
to the smallest possible fluid volume
inside the accumulator during system
operation.
The amount of fluid that is expelled, or
supplied, to the hydraulic system is V,
where V = V1 - V2
A small amount of fluid should remain
inside the accumulator at P1, in order
to prevent the bladder from rubbing or
chaffing against the fluid port poppet
which will cause bladder damage.
Therefore the precharge pressure, P0,
should always be slightly lower than the
minimum working system pressure, P1.
92 INNOVATIVE FLUID POWER
V0 = effective gas volume of the accumulator
(this an internal net volume)
V1 = gas volume at p1
V2 = gas volume at p2
Diaphragm
1 The diaphragm accumulator is precharged
with nitrogen to system design specified
precharge pressure prior to accumulator
installation.
The expanded, pressurized diaphragm
causes the integral poppet in the
diaphragm to close over the fluid port
opening, preventing the diaphragm from
extruding into the fluid port.
No fluid is inside the accumulator at this
step until the accumulator is installed
in the hydraulic system and the system
pressure becomes greater than the
precharge pressure, P0.
Once the system working fluid pressure
becomes greater than P0, the diaphragm
with an integrated poppet, will begin to
compress and cause the integral poppet
to move away from the fluid port opening.
2 The accumulator is installed in the hydraulic
system and the fluid is increased to the
maximum working system pressure, P2. This is
often called charging the accumulator.
At P2, the gas volume in the diaphragm
accumulator is V2.
At this step the maximum amount of fluid
possible for a particular system pressure
range is inside the accumulator and the
fluid is compressing the diaphragm and
nitrogen gas to smallest gas volume.
3 During operation, the minimum working
system pressure, P1, is reached and the
gas volume is now V1. This is often called
discharging the accumulator.
P1 is the maximum gas volume during
hydraulic system operation and correlates
to the smallest possible fluid volume
inside the accumulator during system
operation.
The amount of fluid that is expelled, or
supplied, to the hydraulic system is V,
where V = V1 - V2
A small amount of fluid should remain
inside the accumulator at P1, in order to
prevent the diaphragm from rubbing or
chaffing against the shell which will cause
diaphragm damage.
Therefore the precharge pressure, P0,
should always be slightly lower than the
minimum working system pressure, P1.
T0 = temperature at precharging
T1 = minimum ambient temperature
T2 = maximum ambient temperature
Piston
1 The Piston accumulator is precharged with
nitrogen to system design specified precharge
pressure prior to accumulator installation.
The pressurized nitrogen will cause the
piston to move completely over to the
fluid port side.
No fluid is inside the accumulator at this
step until the accumulator is installed
in the hydraulic system and the system
pressure becomes greater than the
precharge pressure, P0.
Once the system working fluid pressure
becomes greater than P0, the fluid
pressure will begin to compress the gas
by overcoming the precharge pressure,
and cause piston to move away from the
fluid port opening.
2 The accumulator is installed in the hydraulic
system and the fluid is increased to the
maximum working system pressure, P2. This is
often called charging the accumulator.
At P2, the gas volume in the piston
accumulator is V2.
At this step the maximum amount of fluid
possible for a particular system pressure
range is inside the accumulator and the
fluid is exerting force on the piston and
compressing nitrogen gas to the smallest
gas volume.
3 During operation, the minimum working
system pressure, P1, is reached and the
gas volume is now V1. This is often called
discharging the accumulator.
P1 is the maximum gas volume during
hydraulic system operation and correlates
to the smallest possible fluid volume
inside the accumulator during system
operation.
The amount of fluid that is expelled, or
supplied, to the hydraulic system is V,
where V = V1 - V2
A small amount of fluid should remain
inside the accumulator at P1, in order to
prevent the piston from impacting the end
cap for any system cycle.
Therefore the precharge pressure, P0,
should always be slightly lower than the
minimum working system pressure, P1.
PN#02068195 / 04.13 / ACU1102-1326
 Sizing Accumulators
Accumulators
Bladder Diaphragm Piston

Precharge Recommendations
For energy storage: For shock absorption: For pulsation dampening:
p0 = 0.9 x p1 p0 = (0.6 to 0.9) x pm p0 = (0.6 to 0.8) x pm
p1 = minimum working pressure pm = median working pressure at free flow pm = median working pressure

Temperature Effect
Due to the Ideal Gas Laws, the precharge pressure of an accumulator is affected by the ambient temperature of the accumulators operating
environment. Given the constant volume of an accumulator shell when the temperature rises, the gas pressure will increase and conversely
as the temperature goes lower, the gas pressure decreases. This temperature effect on precharge gas pressure will affect operation of the
accumulator in a hydraulic fluid system. Therefore it is critical to consider the precharge pressure at T2, maximum ambient temperature, and T1,
the minimum ambient temperature, when sizing an accumulator to ensure that the accumulator is sized large enough to operate properly over the
entire operating ambient temperature range. The formula below describes the ambient temperature and precharge pressure relationship to any
temperature. Refer to the sizing example on page 95 to see how the formula is applied in the sizing calculation process.

Fahrenheit Celsius
p0 @T0 = p0 @Tx x
(T0 + 460
Tx + 460 ) p0 @T0 = p0 @Tx x
(T0 + 273
Tx + 273 )
T0 = precharge temperature in F T0 = precharge temperature in C
Tx = actual ambient operating temperature in F, where Tx is Tx = maximum operating temperature in C, where Tx is
T1 Tx T2 T1 Tx T2
p0 @T0 = gas precharge pressure at precharge ambient p0 @T0 = gas precharge pressure at precharge ambient
temperature temperature
p0 @Tx = gas precharge pressure at maximum ambient operating p0 @T2 = gas precharge pressure at maximum ambient operating
temperature, where Tx is T1 Tx T2 temperature, where Tx is T1 Tx T2

PN#02068195 / 04.13 / ACU1102-1326 INNOVATIVE FLUID POWER 93

 Sizing Accumulators
Gas Behavior
The compression and expansion processes
taking place in hydro-pneumatic accumulators Correction factor Ci Isothermal Determine the following:
are governed by the general gas laws. change of condition Necessary accumulator size, taking into
The following applies for ideal gases: account the real gas behavior by using
1.7
p 0 x V0n = p1 x V1n = p2 x V2n correction factors
where the time related change of state is 1.6 Calculate gas precharge pressure p0 at 68F
represented by the polytropic exponent n. (T0 )
For slow gas expansion and compression 1.5
Select accumulator size and type

correction factor Ci
processes which occur almost isothermically,

ma
the polytropic exponent can be assumed to Solution:

xw
1.4
be n = 1.

or
Since it is a rapid process, the change of

ki
pr

ng
For rapid processes, the adiabatic change of 1.3 es
condition of the gas can be assumed to be
su
state can be calculated using n = k = 1.4 (for re
nitrogen as a diatomic gas)
p2
=4
adiabatic.
1.2 00
ba
For pressures above 3000 psi the real gas 30
r (58
00 p
1. Calculation for the required ideal gas volume:
0b si)
behavior deviates considerably from the ideal 1.1
ar (
4350 a) gas precharge pressure at T2:
200 psi)
one, which reduces the effective fluid volume b ar
(2900 p
V. In such cases a correction is made which si) p0 @T2 = 0.9 x p1 = 0.9 x 1500 = 1350 psi
1.0
takes into account an adiabatic exponent (k) 1 2 3 4 5 b) gas precharge pressure at T1:
even greater than 1.4; n = k > 1.4. By using the
following formulas, the required gas volume V0 pressure ratio p2/p1 T1 + 460
p0 @T1 = p0 @ T2 x
can be calculated for various calculations. T2 + 460
For low pressure applications of less than 150 Correction factor Ca Adiabatic
psi absolute gas pressures must always be change of condition 75 + 460
used in the formulas. p0 @T1 = 1350 psi x = 1245 psi
V 1.7 120 + 460
V0 = V V c) ideal gas volume:
( )
p0 1/n
( ) p0 1/n V0 = V0 = 1/n
ma

1/n V V
( ) ( () ) (
1.6
V P0 P 0 p , (T )
)
xw

p1 p2 V =
0.714
p , ( T )
0.714 V0, =
V0 = V
Calculation Formulas
( ) ( )
ideal
or

V
0 1 0 1

( ) ( )
0
P1p 1/n P2p p1/n 0.714
P0@(T1) 0.714
p2 =P0@(T1)
( ) ( )
kin

p0 1/n p0 1/n 1.5 V0 idealV =

V =1
correction factor Ca

0 0

( ) ( )
p1 p2
0
P 1
p0, (T1) 0.714 Pp02, (T1) 0.714
pr

( ) ( )
0
p1V p2 p0, (T1) 0.714 p0, (T1) 0.714
es

re
su

V0 = 1.4 p2
p1 15V p2 p1 p2
polytropic: =

( ) ( )
Vp0 1/n p0 1/n 40
V V=0 = 0b
1.35
V0 = V a

(( )) (( ))
p1 p2 1.3 0
30 r( 0.714 0.714
p508, 0(0T1) 0.714 p0, (T1)0.714 V =
( ) ( ) 0V
V0 = 0 b 1150 1150 0,ideal = = 3.95 gals.
p0 p0 ps ideal
15
V
( ) ( )
ar
p1 p2 V P 0 P 0 (
15004 p
350 1
i) 15
3000 p
V = 1245 0.714 1245 0.714
1.2 V0 =
2
2 00 V = psi
V0 =
( ) ( )
isothermal: )
0
1500 3000
( ) ( )
Pp1 P2 p b ar 0
1150 0.714 1150 0.714
( ) ( ) ( ) ( )
(290 0.714
p0 p0 0 0 0 ps1150
i)
1150 0.714
(n=1) 1.1 p p 1500 15 3000 1500 3000
p
V1
p2 1 2
2. Calculation for the required real gas volume:
V0 = V0 =
V
( ) ( ) ( ) ( )
1150 0.714 a) Determine the adiabatic correction factor, Ca
1.0 0.714
V 0 = p0 p0 1 V2 1150 3 4 5
adiabatic:
( ) ( )
pp1 0 0.714p2 p0 0.714 V0 = 1500 3000 p2 3000psi
0.714 V ratio0.714
pressure p2/p1
( ) ( )
(n = k = 1.4) = =2
p1 pV V0 = P 0 P 0
p1 1500psi
V0 = 2

( ) ( )
P1p 0.714 P2p 0.714
( ) ( )
Correction factors to take into account
p0 0.714
p1 V the preal
p0 0.714Sizing Example
p1
0
p2
0
From the correction factor for adiabatic

( )
T + 460 change condition graph, using the 3000psi
( )
2
gas behavior(2 V0 = An additional operation is 0to be added to an curve: T0 + 460
T + 460
( ) ( )
p0 0.714 p0 0.714 existing machine which requires 1.35 gallons
( CTa2T+0 1.16
+460
)
2
For isothermal change of condition: 460
V0,real = Ci x V0,ideal or
p1 p2 of oil in 2.5 seconds
system must operate betweenT3000
for
(
optimal
) operation.
T0 + 460
+ 460psi and
The
b) Real gas T + 460
volume:
( )
2

1500 psi. The operating 68 + 460 2

( )
V0,real = Videal ambient temperature 68
140 + 460 hydraulic V0, real = C x+V460 =1.16 x 3.95 gal.
range is 75 to 120F. The
( )
machines a 0, ideal
T0 + 460 12068++gal.460
Ci
for adiabatic change of condition:
fluid pump is sufficient to fully
accumulator in the 8 second machine ( )
T2 +68 recharge
460
140 + 460
+ 460 the
dwell

( = 4.6
140 + 460 )460
3. Select actual accumulator size by rounding
time. Total machine cycle time = 10.5s. up to nearest nominal size accumulator
V0,real = Ca x V0,ideal or
Vreal = V0,ideal
Given:
maximum system working140
( )
68 + 460
+ 460
pressure
listed in catalog:
Selected size: 5 Gallon = 20 Liter
Ca
p2 = 3000 psi
The Ci and Ca can be determined from the fol-
lowing Correction factor graphs. minimum system working pressure 4. Calculation of gas precharge
p1 = 1500 psi pressure p0 at 68F:
Calculate the ratio of Max/Min pressure, p2 /p1.
required fluid volume of the system p0 @ T0 = p0 @ T2 x
( )
On the graph find the intersection of p2 /p1 and T0 + 460
the maximum working system pressure p2, V = 1.35 gallons
= 1350 psi x
which is shown as a curve on the graphs for maximum ambient operating temperature T2 + 460
either an isothermal or adiabatic change of T2 = 120F = 1230 psi
condition.
minimum ambient operating temperature 3. Selected: Size 20 (5 gallon)
Project the intersection point to the Y-axis to
determine the appropriate correction factor, T 1
= 75F Recommended Model: SB330-20A1/112S-
C or C 210C, Precharged to 1230 psi at 68F
i a.

94 INNOVATIVE FLUID POWER PN#02068195 / 04.13 / ACU1102-1326

 Sizing Accumulators
Pulsation Dampeners & Suction Flow Stabilizers
On the suction and pressure side of piston pumps almost identical
conditions regarding non-uniformity of the flow rate occur. Therefore
the same formulas for determining the effective gas volume are used
for calculating the dampener size. That in the end two totally different
V0 V0
dampener types are used is due to the different acceleration and
pressure ratios on the two sides.
Not only is the gas volume V0 a decisive factor but also the
connection size of the pump has to be taken into account when
selecting the pulsation dampener. In order to avoid additional cross
section changes which represent reflection points for vibrations, and
also to keep pressure drops to a reasonable level, the connection
cross section of the dampener has to be the same as the pipe line.
The gas volume V0 of the dampener is determined with the aid of the
formula for adiabatic changes of state.
suction side pressure side
A simulation of the pressure performance can be carried out by
means of a computer program for real pipe line conditions.
V V
V0 (l) = V0 (in3) =
100 0.714 100 0.714
Formulas 0.695 x 1 -
100 + x Types of 0.695
Pump1 - 100 + X z k
V Gear Pump V 7 - 14 0.1 - 0.3
3
V0 (l) = V0 (in ) = Pump
Piston 2.36 2
x
100 10.714
- 11 0.01 - 0.6
0.714 0.13 3.15
100
0.695 x 1100
- 0.695
e.g. 1 - 4
X (%) = 100 + x - 100
3
V0 (in ) = 100 + X 1 0.6
0.714
V 1.4 100 2 0.25
1- 0.695 1 -
100 +2 2.5
0.695 x V0 3 0.13
0.13 2.36 x 3.15
100 3
V0 (in ) = 4 4 0.12
X (%) = - 100 0.714
V 1.4 100 5 0.05
1- 0.695 1 -
100 + 2.5 6 0.13
0.695 x V0
V 7 0.02
V0 (in3) =
V (l) = kq 100 9
0.714 0.01
0.695 1 -
100 + X
Calculation Example

p - pm p - pm V
X (%) = x 100 = x 100 V0 (in3) =
Parameters:
pm pm 0.13 2.362 x 0.714
3.15
Single 3acting 3-plunger 100
V (in ) = 0.695 1 - pump4
0
piston diameter 100 + X
2.36 inches (60 mm)
0.714
p - pm
V0 = required gas volume p - pm 100
X (%) = x 100 = x 100 piston stroke 0.695 1 - 3.15 (80 mm)
V = fluctuating fluid pvolume 100 +2 0.5
m pm rpm 370 0.13 2.36 x 3.15
q(l) = stroke volume per cylinder flow rate
V0 (in3
)= 464.44 gpm (244 l/min.)
p - pm = p - pm = amplitude of pressure fluctuations operating temp. 68F 0.714
100 (20C)
V 0.695 1 - V
X = residual pulsations V0 (l) = V0 (in ) = 100 + 0.5
operating pressure 3
0.714 0.714
100 pressure side 3625 psi 100 (250 bar)
p = max. working pressure 0.695 x 1 - 100 + x 0.695 1 -
suction side 58 psi 100 + X (4 bar)
p = min. working pressure
Required: 1
pm = pump flow rate or pressure in the suction line 2
V Suction stabilizer 0.13 2.36
V xpulsation
3.15of 2.5%
V0 (l) = 100 1Vflow D
(in 3
) =
for a residual
4
= Coefficient of cyclic variation of the pump 0
p x Vx0dampener 3
X (%) = 100 -0.714
100 Pulsation K E(inx e )= for a residual 100 pulsation
0.714 of 0.5%
0.714
0.695 x cylinders
z = No. of compressions / effective 1V- per 0.695 1 - 100
+ x revolution
1.4
1 - 100 Solution: 1 0.695 1 - 100 + X
factors for other types, i.e. gear, axial, 100 + 2.5
0.695 x and
V0 radial piston a) Determination of required 1 suction flow stabilizer
pumps on request 1 D
px x 1 0.13 250 2.362 x 3.15
980 K Exe
x x
100 V1.62
0 (in x
3 10
)= 9 2.04 x 1011 4x 6.3
X (%) = - 100 0.714
1.4 100
P V 1
0.695 1-
1- 100
V + 2.5
(bar) 0.695 x V0
1 V (in1 3
)= 250
980 SB
Selected: x 0330-4 (see 9 xtable onx page 13)
11100 0.714
1.62 x 10
2
m x v x0.695 2.04
0.4 1 - 10 xp 6.30.714
p
1 D x100p+1 X
pm p x px - p p - pm p2required
0.286 0
K E xme b) Determination
2 x p1 x of - 1 pulsation
x 102 dampener
X (%) = x 100 = x 100 p1
p 1 pm pm 2.36 2
x
V
m 33x) =
V0 (in v2 x 0.40.13 4p1 0.714 3.15
1 D V0 (in ) = x 100 p 0.714
px x t (sec) 0.252 x p2 0.286 0.695 - 2 1000
110
0.714
K2 E x e 980 x 2 x p xx 2000 x -
2.452
0.695 1 x 10.4
- 100 + X
m x v x 0.4 0.714 p

p 4 1 1 100 7
+ 0.714
0.5
V0 (l) = p - pm x 1 p - pm x
X (%) =
p1 0.286 x2 100p=0 x 100 Selected: SB 11330
0.286
P-20 (see table
4.5 61)
on page
2 x p1 x -1pmx 10 p 2 x 7 x - 1 x 10 2 2.36 2
x 3.15
p0 m 7 0.13
0.252 x 3 4
For assistance in sizing pulsationmdampeners,
p 0.714 and suction stabilizers,980 x
x v2 x 0.4shock absorbers, Vx0 (in
2000 ) =x 2.452 x 0.4
4 7 0.714 0.714
x 1
V0 (l) =the HYDAC Accumulator Group at 1-877-GO
please contact HYDAC. x 100
p1 0.286 p 0 11 0.286 0.695 1 - 4.5
2 x p1 x -1 x 10 2 100 + 0.5
p0 2x7x - 1 x 102
7
PN#02068195 / 04.13 / ACU1102-1326 INNOVATIVE FLUID POWER 1 95
1 D
px x
K Exe
 Sizing Accumulators
Energy Storage Form
Name Title

Company E-mail

Address

Phone State Zip

Phone Fax

Please attach any special requirements or drawings to the fax or e-mail.

Operation of Pump
Continuous Operation
Emergency Operation
Maximum Operating Pressure (P2) PSI
Minimum Operating Pressure (P1) PSI
Precharge Pressure at 68F (20C) (P0) PSI
Temperature Range of Environment (T) F
Temperature Range of Fluid or System (TF) F
Pump Flow Rate (QP) GPM
Total Cycle Time of System (TE) Sec.
Number of Actuators (cylinders, etc.) (NV)

Actuator Time Schedule and Flow

QVi = Required Actuator Flow (GPM) Ei = Actuator Start Time Ai = Actuator Shut Down Time
(i = 1 for first actuator, i = 2 for second actuator, etc. up to NV)

QV1 = E1 = A1 =
QV2 = E2 = A2 =
QV3 = E3 = A3 =
QV4 = E4 = A4 =
QV5 = E5 = A5 =

Fluid

Required Mounting Orientation

Country of Final Installation (for country codes please see page 2)

Required Quantity
Annual Usage Target Price Competitor Quantity

Additional Remarks

96 INNOVATIVE FLUID POWER PN#02068195 / 04.13 / ACU1102-1326

 Sizing Accumulators
Shock Applications Form
Name Title

Company E-mail

Address

Phone State Zip

Phone Fax

Please attach any special requirements or drawings to the fax or e-mail.

What is the source of the shock? (i.e. valve closing, pump start, or other - please describe)

At the instance the shock occurs what is the...

Flow rate: GPM
Normal Operating Pressure: PSI ; Maximum Spike Pressure: PSI
The systems maximum allowable design pressure: PSI
Information is required on all piping from the shock source to the anticipated location of the shock absorber (accumulator) .
Please continue to answer the following:
Total Number of pipes: (up to 10 pipes)

Starting at the shock source, please answer the following:

Inner Inner
Length Length
Pipe Diameter Pipe Diameter
(feet) (feet)
(inches) (inches)
1 6
2 7
3 8
4 9
5 10

If the vertical height from the shock source to the anticipated location of the shock absorber is greater than 10 feet
please state this distance.
Vertical Height: feet

Fluid

Required Mounting Orientation

Country of Final Installation (for country codes please see page 2)

Required Quantity
Annual Usage Target Price Competitor Quantity

Additional Remarks

PN#02068195 / 04.13 / ACU1102-1326 INNOVATIVE FLUID POWER 97

 Sizing Accumulators
Pulsation Dampening Form
Name Title

Company E-mail

Address

Phone State Zip

Phone Fax

Please attach any special requirements or drawings to the fax or e-mail.

What type of pump is causing the pulsation?
Please name or describe (ie piston pump, gear pump, etc.)

What is the...
Flow rate: GPM
Pump: RPM
Pump Piston Diameter: (inches)
Pump Piston Stoke: (inches)
Number of Rotating Elements: (3 piston, 13 tooth gear, etc)
Operating Pressure: psi
The systems maximum allowable pressure: psi

Line Size where pulsation dampener will be fitted into:

(The I.D. of the line is what is really required)

Note: A pulsation dampener should be always be installed as close to the pulsation source as possible to optimize its performance. A pulsation dampener
should never be placed greater than 10 ft away from the pulsation source.

Fluid

Required Mounting Orientation

Country of Final Installation (for country codes please see page 2)

Required Quantity
Annual Usage Target Price Competitor Quantity

Additional Remarks

98 INNOVATIVE FLUID POWER PN#02068195 / 04.13 / ACU1102-1326