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Sauer Service on the Road Shanghai

Philip Ng Yuki Bao


General Manager Manager
After Sales Parts & Supply Department
Hoi Tung Hoi Tung

Marko Wippermller Alain Chau Michael Guo


Training Manager Service Manager Service Inspector
. Sauer Compressors Sauer Compressors Sauer Compressors
Sauer Service on the Road Shanghai
Product range

Aircooled compressors

Watercooled compressors
Overview

Heat

Gas (V2, p2, t2),H2O, Oil


Gas (V1, p1, t1) ,H2O
() ,
()

Condensate (H2O, Oil)



Pressure ratio

Pressure ratio p1 stage inlet pressure

p = p2/p1 p2 stage outlet pressure

Influence on compression temperature


Water content

There is always water in the ambient air in vapourized form

The quantity of water will vary with the temperature and relative humidity
of the air

The absolute humidity remains stable during compression


The relative humidity increases during the compression due to the


reduction of the airvolume

Liquid water will form as soon as the relative humidity will increase up to
100% or the air is cooled down below the dewpoint 100%

Intermediate drainage is required


Water content

For Example:
5 m Air with- t =30C und =30% relative humidity contains 30g water
30C30%530

t = 30C
V=5m

t=30C
V=1m

30g

The relative humidity increases due to the compression to 1 m


1
The absolute humidity remains stable
Water table

Moisture content at different dewpoints


Water content in compressed air

European Conditions: Tropical Condition:


t=20C =60% 400 m/h t=45C =90%

?
10g / m3 55 g / m3

?
400 m3/h x 10 g/m3 = 4000 g/h 400 m3/h x 55 g/m3 = 22000 g/h
4 Liters / h 22 Liters / h
Air
Europe 0,2 l / h
Tropical 2 l / h

Drainage interval
Drainage
5min / 3sec !
Europe 3,8 l / h
Tropical 20 l / h
P & ID

- Piping & Instrumentation Diagram


- Shows all parts which are in the process

- Illustrates the process flow


- Included in the Sauer manual
Passat-Series

.
Compression stage

Compression stage consisting of:



Cylinderhead
Valve
Cylinder
Piston
Piston rings

Transfering the heat from the piston to the cylinder Compression chamber

Sealing the compression chamber from the crankcase

Adjusting the lubricating film

Compression rings
Scraper rings
Distribution rings

Oilfilm
Crankcase
Piston rings

- More compression rings on higher stages



- Replacement together with piston pin and piston pin bearing

- Service life of Genuine Sauer Piston rings 4000h
Sauer4000
4000
Cylinder

- Water cooled or air cooled


- With liner or without

- Rips on aircooled cylinders

- Honed surface to build oil pockets

- Not a Wear & Tear part (EC)
Valves

- Combined suction and pressure


- Space saving
- Low maintenance
- Low flow resistance
- Lamellar or concentric type
- Defined dead clearance volume
Sauer
- Typical servicelife for Genuine Sauer Valves
depending on the application / pressure 2000h /
4000h

-2000h
-4000h
Separators
Separators

Air outlet

Air inlet

Swirl insert

Baffle cone

Condensate outlet

Genuine Sauer Separators are maintenance free Sauer


Drainvalves
Drainvalves

Solenoidvalve
- Standard drain interval for 5min / 3sec
53
- Starting relief 15sec 15

- Draining simultaneously
- Normal open
Coolers
Coolers

Honeycomb radiators
12
- Suitable for low pressures
(1st & 2nd stage)
Finned tube coolers
3
For higher pressures 3rd stage
Coolers

Coolers on water cooled compressors


- Cartridge type
- Tubecoolers U
- gas inside
- water outside
Cooler improvement
Cooling water supply

In case cooling water temperatures are too low


Overcooling
Condensation
High wear & tear
Cooling water supply

In case cooling water temperatures are too high


Calcification
Coolers
Water spaces
Overheating especially on 2-stage watercooled compressors
High coking of lube oil
High wear & tear
Proper cooling supply

Coolingwater inlet temperature


little warmer than suction gas temperature
Optimum inlet temperature
30C -35C
Optimum outlet temperature
Freshwater cooling
40C-50C
Seawater cooling
35C-45C
Loss of corrosion protection effectiveness of zinc anodes at temperatures above
Proper cooling supply

If cooling water is too cold


Flow reduction is required
Gas outlet temperature
About 20C above cooling water inlet temperature
Depending only on cooler and compressor design
Cannot be reduced by increasing cooling water flow
Cooling water amount
Rule of thumb

Qcw=
Based on T =15C of cooling water

Pcomp=Installed drive power in kW


Qcw=Required cooling water flow in l/min
Tin= Cooling water inlet temperature in C
Proper cooling supply

Proper cooling supply


Achieve lowest possible gas temperature
Low residual moisture content
Reduces load on purification on filters, dryers,..
Dirt trap at the inlet
Mesh 60-100m
Solenoid valve at the inlet
Normal closed to stop cooling water flow during standstill
Proper cooling supply

Zinc anodes
To protect against corrosion
Thermostatic valve at the outlet
Automatic regulation of cooling water outlet temperature
Manual valve at the inlet
Manual regulation of flow at the inlet
Cooling system supervision by gas temperature switch
Fast increase of gas temperature
Much slower increase of water temperature du to higher heat capacity
Therefore no need for a separate coolingwater temperature switch
Special cases

Operation at 1470rpm /1770rpm


Running time > 15min
Cooling water inlet
Stable 30C-40C
Cooling water outlet
Stable 45C-50C
No control required

Operation at lowers speeds


Cooling water inlet
< 30C
Mandatory
Cooling water solenoid
Thermostatic valve
Temperature monitoring
Temperature monitoring

Temperature switch
Temperature range adjustable
Standard setting 90C rising
90C

Fusible plug
Fixed setting of 121C 121C
Alloy melts at 121C and HP air can
escape through the bore
121C

Only for one time usage
Lube oil circuit
Oil strainer

- Removal of bigger particles


- No real filter (-strainer)



- Maintenancefree

(only cleaning required)
Oil pump

- Gear type oil pump


- Directly connected to the crankshaft
-
- Pumps the oil through an oil gallery in the
crankshaft to the lubrication points
-
Lubricating points
Pressure maintaining valve

Pressure maintaining valve


- maintains the oil pressure to 3 bar
- 3bar
- Fully open during start period with
cold oil (high viscosity)


- Maintenance free
Oil pressure switch

Fitted to pressure side of the oilpump


Oil pressure supervision
Switchpoint 1bar falling (green arrow) 1bar
Switch is active after op rised one time above 1,8bar (Hysteresis)1.8bar

Crankcase ventilation
Insulation ventilation pipe

The oil filler pipe is protected with an insulating hose to


prevent condensation in the pipe

Do not take away this insulating material

Installation

Installation
Place of installation

The place of installation have to be dry and free of dust


The place of installation have to be vented in such way that the heat generated
during operation is dissipated.Only this way

Room temperature while the Sauer compressor is running: + 5 + 55 C


+ 5 + 55 C
Ventilation

The room has to be ventilated


not the compressor!

Only this way!


Wrong ventilation

Wrong Do not blow


ventilation directly

Do not blow
Directly

Blow-by air

Basics: Why we have to look for the right ventilation,


respective cooling water supply?


Blow-by air with water vapour is always entering the crankcase by the
piston and is accumulated there

in mineral oils as
emulsions

in synthetic oils as
water below the oil

Foundation

Flexible ( resilient ) mounting is to


prevent vibrations into the installation
location

A movement when the compressor is
running, is quite normal.

Typical is a Amplitude of 0,3mm
( velocity 30 ..45 m/s)
0.3mm30-45m/s
Due to the movement flexible
connection for delivery air, power
SHORE 40 / 55
SHORE 40 / 55 supply and drainage is required.


Hz
Rigid mounting : is possible, but it is not state of art The natural frequency of the mounting
is between 7 - 12 Hz.7-12
Foundation
Running interval

Pressure switch setting for Start / Stop!


10 .. 20 min running interval is requested.
1020
If less corrosion can occur

50 Oil temp has to


reach min. 50C
while running

We recommend not more then 5 starts per hour!


5

Interfaces (receiving)
Optimum Operation
Drain connection

No back pressure !!!


Connecting the compressor

Hose lines have to be installed free of tension and untwisted!



Operation & Monitoring

Commissioning
Operation and monitoring


Stage pressure diagram

Chapter 6.4
Watercooled vs. AircooledVS

Watercooled Aircooled
Watercooled vs. AircooledVS
Performance

2.Stage watercooled 3.Stage aircooled


2 3
Stages 2 3

Maximum Pressure 30bar(g) 40bar(g)

Max. Air inlet / outlet 55C / 90C 55C / 90C


temperature

Pressure ratio 5-6 below 3,5


3.5
Compression Above 200C Below 200C
temperatures 200 200
Lubrication system Forced / Splush Forced / Splush

Weight (average) 770kg 700kg

Heat Dissipation to amb. 8 kJ/s 44 kJ/s

Installation

2.Stage watercooled 3.Stage aircooled


2 3
Soundpressure @ 1m 89dB 93dB
@1m
Cw shut off valve Yes No

Cw system required Yes No

Cw pump Yes No

Cw piping Yes No

Cw monitoring Yes No

Cw Safety valves Yes No

Cw valves / filters Yes No


/
Maintenance

2.Stage watercooled 3.Stage aircooled


2 3
Airfilter 1000h 1000h

Oil 1000h 1000h

1st stage Valve1 2000h 4000h

2nd stage Valve2 1000h 4000h

3rd stage Valve3 - 2000h

Piston rings/ pins & 4000h 4000h


bearings/
Flexible gear rim 4000h 4000h

Drain valves 4000h 4000h


Maintenance

2.Stage watercooled 3.Stage aircooled


2 3
Particle trap 1000h -

Zinc protection 1000h -

Bursting discs 1000h -

Costs / h Sauer EC 2,59 - 4,67 1,85 - 3,57

Summary

Watercooled Aircooled
Summary

Watercooled Aircooled
Summary

Watercooled Aircooled

Constant
discharge Less
temperature temperature

Summary

Watercooled Aircooled
Summary

Watercooled Aircooled

Low noise level


Less
maintenance
costs
Constant
discharge Less
temperature temperature

Summary

Watercooled Aircooled
Advantages
Questions?
Thanks for listening
Sauer Easy Care Concept
Sauer Easycare

Your maintenance have never been so easy !

Chau
16.03.15
Rev1
Sauer Easy Care

A life cycle concept for your Sauer Compressor



Preventive or Corrective Maintenance ?

Challenges for Today's Ship Operators



Less time and more tasks for engineers, superintendents
and procurement
Achieving competitive operational costs within the budget

High reliability for important equipment
Corrective Maintenance

Very high risk of breakdowns


in case of corrective maintenance

Thats not acceptable!

Preventive Maintenance

We recommend the Sauer Easy Care Concept:


With clearly defined exchange intervals and precise
maintenance instructions !
for highest safety and operational availability

Time and economic advantages by using Maintenance Kits

Change before it break policy !
Usage of fresh parts
Avoid check and replace if necessary !
Continued reliability !
Sauer Easy Care

Maintenance and its preparation


is much easier!

Easy Integration into the
Ship Maintenance System

Sauer Easy Care

Sauer Easy Care


Kits reference
numbers are related
to maintenance
routine
Easycare

New maintenance
procedures eliminate
uncertainties by
check and replace if
necessary wording
Precise Instructions !

Sauer Easy Care content


Sample maintenance schedule

1/3 2
Sauer Easy Care content
Sample maintenance schedule

4
Table of contents
Sauer Easy Care

Maintenance cost per running hour to have a clear view of budget



Sauer Easy Care: Advantages

What are the Benefits of Sauer Easy Care?


Price reduction of up to 23% 23%
compared to single orders of the parts
Only one part number for one maintenance

Life Time Guarantee of the maintenance parts

Time reduction on board and at office



Avoiding wrong orders
All parts will be replaced before they fail

No General Overhaul necessary on board

Partnership with maker

What is the difference between Greymarket & Sauer?


Warranty on Service Life?
Benefits of partnership

Or buy from partners with full warranty and after sales support?

Dialogue with maker


Only known issues can be solved / avoided beforehand
Plausibility analysis
Every spare part request is checked for plausibility and
corrected if required

Know how transfer


Maintenance / Repair instructions / Bulletins
//

Saving operation costs


Advantages

Stage valves:

- In the former maintenance schedule, there was no regular exchange of valves


recommended.
- Valves were overhauled by lapping the valve body and exchanging of plates and springs

- Servicelife of valves were very various due to quality of work on board

- Check and replace if necessary was the standard formula

- Now with Sauer Easy Care the guaranteed service life for the valves on 3-stage air-cooled
compressors is:Easycare
4000h for 1st and 2nd stage 124000
2000h for 3rd stage 32000
Sauer Easy Care: Advantages

Piston pins and needle roller bearings:

GUARANTEED Service life of


Genuine Sauer piston pins & bearings: 4000h
Sauer4000
Replacement of piston pins and bearings
before they break and create further
damages on life time parts.


Advantages

Cylinders and pistons:

Genuine Sauer cylinders are maintenance free


Sauer
The compressors end of service life is determined by the wear of the cylinders
(this should be measured every 4000 running hours)
4000
Sauer Easy Care: Advantages

Piston rings: Gas

Backlash

Gas

Cylinder Piston Pistonring

GUARANTEED Service life of


Genuine Sauer piston rings: 4000h
Sauer4000
Replacement of piston rings before
they can create wear on life time parts.

Main- and conrod bearings, shaft seals

Due to big crank shaft sizing the bearings have to be also big

- Crank shaft bearings and connecting rod bearings are oversized and
designed for the life time of the compressor (50.000h)
5
- The shaft seals only have to be replaced if leaking
- The wear and tear area of the connecting rod bearings (big end) consist
of 3-layers (same as for diesel engines). They have very little wear, if
oil change and maintenance are executed according to Sauers
recommendation (life time >50.000 rhrs)
Sauer
5
Crankdrive

No maintenance zone! Crank drive and crankshaft should


only be touched in case of emergency

Summary

All parts will be replaced before they fail

Throughout the whole service life of the compressors corrective


maintenance at the drive mechanism is not necessary

The compressors end of service life is determined by the wear of
the cylinders (this should be measured every 4000 running hours)
4000
Service life 50.000 hours in average
5
Then Sauer offers exchange compressors
Sauer
News from Sauer Service

News
from
Sauer After Sales Service
Sauer
News: Twinkle Valve
Sauer twinkle valve TM now in the field Sauer
Sauer has made the next step for the new twinkle valve TM. This new development is again a
step on the ladder of Sauers ongoing development work on its high quality and reliable
products.
After several years of testing the twinkle valve TM on many vessels worldwide Sauer started
serial production beginning of 2014. This spectacular new valve will be used at the 3 stage air-
cooled compressors (WP81L / WP101L and WP121L / WP151L) at the 3rd compression stage.
At these compressors the new twinkle valve TM replaces the old design of 037158.
2014

037158

When comparing the pictures above you will see that beside the Twinkle eye kind of shape of
the compression openings, the second major new design feature is the absence of bolts and
nuts. The Sauer twinkle valve TM cannot be opened anymore. This feature was requested by
many customers after introduction of Sauer Easy Care to the market.

03.05.2016 24
News: Brochure Heat Dissipation

New Brochure Heat Dissipation at air-cooled compressors

03/05/2016 25
News: New Drainage Intervalls

New Drainage Intervalls for Shipping

03/05/2016 26
News: Certificate

New
Certificate
of
Conformity and Authenticity

03/05/2016 27
Solenoid drain valves

Repair recommendations for drain valves


- Replacing drain valves (solenoid valves) are not part of periodical planned maintenance

- Overhauled only every 4,000 h 4000


- For Sauers standard valve (220240 V/ 50 60 Hz) we offer repair kit (038528)
which includes a new diaphragm, two o-rings and the conical spring
Sauer(220240 V/ 50 60 Hz) 038528)
2
Summary

Easiest scheduling
(for crew, shipping company and Sauer)Sauer

Transparency in carrying out the maintenance work



(clearly defined exchange intervals, precise instructions)
Utmost operational dependability
(Replace maintenance parts by use of fresh parts shortly before malfunctions occur
)
Low operating costs
(long maintenance intervals, in practice no repair, more favourable spare part kits by
comparison to prices per item
)
Clear view of your budget
(easy predictable running costs in /h, for full cost transparency)

Incomparable concept including guaranteed high quality
Genuine Sauer PartsSauer
Operation

Important Checks during operation

Checking lube oil

Checking for leakages

Listening for abnormal noises


Intermediate drainage 5min / 3s


3

Max. amount of starts per hour: 4


4

Monitoring running hours


Thank you for your Attention