Sauer Service on the Road

Cyprus 2014

Wippermueller
December 2014
Rev1
Product range

Aircooled compressors

Watercooled compressors
Overview

Heat

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

Gas (V1, p1, t1) ,H2O

Condensate (H2O, Oil)

 Thermodynamics

The physical state of a gas is defined by three parameters:

-Temperature t (°C, °K or °F)
-Pressure p (bar, Pascal, PSI, ...)
-Volume V (m³, Liter, cft, ...)

-Volume 
-Pressure 
-Temperature 

Any change on one parameter has influence on the others.

Compression with multistages

Compression with 2-stages

2. Stage
1. Stage
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

Intermediate drainage is required

 Water content

For Example:
5 m³ Air with- t =30°C und =30% relative humidity contains 45g water

t = 30°C
V=5m³

t=30°C
V=1m³

45g

The relative humidity increases due to the compression to 1 m³

The absolute humidity remains stable
Water table

Moisture content at different dewpoints

Water content in compressed air

European Conditions: Tropical Condition:

t=20°C =60% 400 m³/h t=45°C =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
.
 Piston rings

 Transfering the heat from the piston to the cylinder

 Sealing the compression chamber from the crankcase
Compression chamber
 Adjusting the lubricating film

 Compression rings
 Scraper rings
 Distribution rings

Oilfilm
Crankcase
Piston rings

Lubricant film
Compression chamber Gas

Sealing between C.chamber & Crankcase

Pistonring Heat transfer

Adjusting and distribution of the oil film

Cylinder

Piston

Crankcase
Piston rings

Compression rings
M-Ring (DIN70911)
Conical surface with 45´ / 60´
„Top“ Marking
 Sealing
 Scraping M-Ring

Scraping off oil with the edge

 Piston rings

Compression ring
Rectangular ring (R-Ring)
Cylinder
 Sealing
 Less scraping of the oil (compare to M-Ring)
Piston

Oilfilm R-Ring
 Piston rings

Scraper rings

N-Ring
 Adjusting the oilfilm

S-Ring (DIN70911)
 Guiding the oil to the cylinder
 Pressed only by internal tension
 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
- Typical servicelife for Genuine Sauer Valves
depending on the application / pressure 2000h /
4000h
 Valves

Concentric or lamellar type

-Replacement of the innerparts and relapping of the
valve body is not recommended
-Innerparts are not available any more
-Replacement as a whole after 2000h / 4000h
Separators
 Separators

Air outlet

Air inlet

Swirl insert

Baffle cone

Condensate outlet

Genuine Sauer Separators are maintenance free

Drainvalves
 Drainvalves

Solenoidvalve
- Standard drain interval for 5min / 3sec
- Starting relief 15sec
- Draining simultaneously
- Normal open
Safety valves
 Safetyvalves

- Protection against over pressure

- After each stage
- In the cooling water system
- In the receiver
- Fixed setting for inter stages
- Final setting (5% of final pressure)
Coolers
 Coolers

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

Coolers on water cooled compressors

- Cartridgetype
- Tubecoolers
- gas inside
- water outside
Cooler improvement
Temperature monitoring
Temperature monitoring

Temperature switch
 Temperatur range adjustable
 Standard setting 90°C rising

Fusible plug
 Fixed „setting“ of 121°C
 Alloy melts at 121°C and HP air can
escape through the bore
 Only for one time usage
Temperature monitoring

- Bismuth
- Lead
- Tin
Temperature monitoring
 Crankcase ventilation

Crankcase ventilation
- Leakage air from all stages
- Transport of water steam
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
Summary

.
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.
Room temperature while the Sauer compressor is running: + 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
 Ventilation

 Direct ventilation causes an overcooling of the compressor and lead to

condensation in the machine.

 The consequences are:

 Drastically shorten the servicelife of all components, e.g. valves, cylinders,...
 Contaminated lube oil
 Reduced lubrication properties  increased wear & tear
 Damages by corrosion
 Water hammer
Proper ventilation

Only Indirect ventilation air flow

Ventilation
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)
• Due to the movement flexible
connection for delivery air, power
supply and drainage is required.

SHORE 40 / 55 • The natural frequency of the mounting

SHORE 40 / 55
is between 7 - 12 Hz.

Hz Rigid mounting : is possible, but it is not state of art

Foundation
Suction conditions

Suction air inlet condition

Max . 55°C
900mbar … 1300 mbar abs. Pressure

Interfaces (receiving)
Maintenance space

A = 500mm recommended for maintenance

Interfaces (receiving)
Running interval

Pressure switch setting for Start / Stop!

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

Oil temp has to

reach min. 50°C
while running

We recommend not more then 5 starts per hour!

Interfaces (receiving)
Drain connection

No back pressure !!!

Connecting the compressor

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

Combi pressure switch

Combi switch
Start /Stop

Non return valve

Operation & Monitoring

Commissioning
Operation and monitoring
Stage pressure diagram

Chapter 6.4
 Questions?

Thank you for your Attention