INTERSHIP NAVIGATION TRAINING CENTER, INC

MANILA, PHILIPPINES
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
Contents
Page
General hints
1. Technical data 3
2. Design 4
3. Commissioning and Operating Instructions/Operation Saet! Instructions "
4. #aintenance 1$
". Operating Trou%les and their &limination 11
'. Starting procedure o air cooled sa(er compressor 12
). *al(e +ssem%l! 13
,. -ongitudinal and Cross Section 14
.. Compressor unit /ith electric motor 1"
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
.
Air compressor
Compressed air has man! uses on %oard ship0 ranging rom diesel engine starting to
the cleaning o machiner! during maintenance. The air pressure o 2" %ar or more
are usuall! pro(ided in multi1stage machines. 2ere the air is compressed to a higher
pressure in the ne3t stage0 and so on. The t/o stage cran4 machine is pro%a%l! the
most common0 and one t!pe is sho/n in 5igure ).1.
+ir is dra/n in on the suction stro4e through the irst stage suction (al(e (ia the
silencer/ilter. The suction (al(e closes on the piston upstro4e and the air is
compressed. The compressed air0 ha(ing reached its irst stage pressure0 passes
through the deli(er! (al(e to the irst stage cooler. The second stage suction and
compression no/ ta4e place in similar manner0 achie(ing a much higher pressure in
the smaller0 second stage c!linder. +ter passing through the second stage deli(er!
(al(e0 the air is again cooled and deli(ered to the storage s!stem.
The machine has a rigid cran4case /hich pro(ides support or the there
cran4shat %earings. The c!linder %loc4 is located a%o(e and replacea%le liners are
itted in the c!linder %loc4. The running gear consists o pistons0 connecting rods and
the one1piece0 t/o1thro/ cran4shat. The irst stage c!linder head is located on the
c!linder %loc4 and the second stage c!linder head is mounted on the irst6 each o
the head carries its suction and deli(er! (al(es. + chain dri(en rotar!1gear pump
pro(ides lu%ricating oil to the main %earings and through internall! drilled passages
in the cran4shat to %oth connecting rod %earings. Cooling /ater is supplied either
rom an integral pump or the machiner! space s!stem. The /ater passes into the
c!linder %loc4 that contains %oth stage coolers and then into the irst and second
stage c!linder heads. + /ater 7ac4et saet! (al(e 85igure ).29 pre(ents a %uild1up o
pressure should a cooler tu%e %urst and compressed air escape. :elie (al(e are
itted to the irst and second stage air outlets and are designed to lit at 1$; e3cess
pressure. + usi%le plug is itted ater the second1stage cooler to limit deli(ered air
temperature and thus protects the compressed air reser(oirs and pipe /or4s.
Cooler drain (al(es are itted to compressors. <hen these are open the machine
is =unloaded> and does not produce compressed air. + compressor /hen started
must %e inn the unloaded condition. This reduces the starting tor?ue or the machine
and clears out an! accumulated moisture in the s!stem. This moisture can aect
lu%rication and ma! produce oil//ater emulsions0 /hich line the air pipelines and
could lead to ires or e3plosions.
The compressor motor is started and the machine runs up to speed. The
lu%ricating oil pressure should %e o%ser(ed to %uild up to the correct (alue. The irst
stage drains and then the second drains are closed and the machine /ill %egin to
operate. The pressure gauge coc4s should %e ad7usted to gi(e a stead! reading.
<here manual drains are itted the! should %e slightl! opened to discharge an!
moisture0 /hich ma! collect in the coolers. The cooling /ater suppl! should %e
chec4ed0 and also operating temperatures0 ater a period o running loaded.
To stop the compressor0 the irst and second stage coolers drain (al(es should %e
opened and the machine run unloaded or t/o to three minutes. This unloaded
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
running /ill clear the coolers o condensate. The compressor can no/ %e stopped
and the drains should %e isolated i the machine is to %e stopped or a long period.
+utomatic compressor operation is ?uite usual and in(ol(es certain additional
e?uipment. +n unloaded must %e itted to ensure the machine starts unloaded0 and
once running at speed /ill =load> and %egin to produce compressed air. *arious
methods o unloading can %e used %ut marine designs a(or either depressors0
/hich hold the suction (al(e plates on their seats0 or a %!pass /hich discharges to
suction. +utomatic drains must also %e itted to ensure the remo(al o moisture rom
the stage coolers. + non1return (al(e is usuall! itted as close as possi%le to
essential itting /here unloaders are used.
The compressed air s!stem or the suppl! o starting air to a diesel engine is
descri%ed in Chapter 2. Control or instrument air supplies ha(e particular
re?uirements /ith regard to %eing moisture and oil ree and /ithout impurities. +
special t!pe o oil1ree compressor ma! %e used to suppl! control air or it ma! %e
treated ater deli(er! rom an ordinar! air compressor. This treatment results in the
air %eing iltered and dried in order to remo(e (irtuall! all traces o oil0 moisture and
an! atmospheric impurities.
#aintenance in(ol(es the usual chec4s and o(erhauls common to reciprocating
machiner!0 e.g. cran4case oil le(el0 cooling /ater s!stem0 operating temperatures
and pressures0 etc. The suction and deli(er! air (al(es or each stage /ill present
the most /or4 in an! maintenance schedule. These (al(es are automatic0 re?uiring
a small pressure dierential to operate.
The constant rapid opening and closing action o the (al(es ma! re?uire the
seats to %e reaced. O(erheating0 use o incorrect lu%ricating oil0 or the presence o
dirt ma! result in stic4ing or pitting o the suraces. The (arious %uer plates0 spring
plates0 (al(e plate and seat /hich ma4e up suction or deli(er! (al(e can %e seen in
5igure ).3. The (al(es should %e stripped and all parts careull! cleaned and
e3amined0 an! /orn parts replaced and the (al(e seat and plate lightl! lapped
separatel! on a lat surace %eore reassem%l! to ensure a good seal.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
1. Technical a!a
Compressor t!pe <P 1" -
@um%er o c!linders 2
@um%er o stages 2
C!linder A stage I 1$$ mm
C!linder A stage II 4' mm
Piston stro4e 42 mm
Operating pressure ma3. 4$ %ars
Speed ma3. 2$$$
1
/min
Oil illing capacit! 10" l
11 %et/een dipstic4 mar4s $0" l
Oil %rand according to oil recommendation
Stue / stage I , %ar
Stue / stage II " ; o(er inal pressure
Direction o rotation on the right0 /hen loo4ing at dri(ing
side
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
". esi#n
".1 Per$ormance an% se!&'p
The single acting compressors /ith t/o stages compress atmospheric air in t/o *1li4e
arranged c!linders to a inal pressure up to 4$ %ars. Due to the arrangement o the c!linders
and a mostl! %alanced gear it is e(en a high speed pro(ided a smooth running so that an
arrangement /ithout a %ig machiner! oundation is possi%le.
The recooling o the air compressed in the I. and II. Stage is made in in1pipe coolers. These
are arranged surrounding the l!/heel e?uipped as radial (entilator and are placed in the ull
airlo/ o the (entilator.
+ case co(ers the radial (entilator and the coolers and the leads the airlo/ onto the
c!linders.
The three phase e1motor model B 3/B." is directl! langed to the coupling cage o the
cran4case. The po/er transmission is made (ia a le3i%le coupling. Diesel engines are
mounted (ia special langed. The po/er transmission is made serial %! a centriugal clutch.
The oil and /ater separator is mounted to the coupling case.
"." Cons!r'c!ion %e!ails
Gear The cran4shat is t/ice in roller %earings. The connecting rod %earings
are e?uipped as slide %earings0 the piston pin o the I. stage goes in a
%ronCe %rush0 the piston pin o the II. stage in a needle roller %earing.
-u%rication The /hole gear lu%rication is made %! splash lu%rication. Onto the
connection rods there are ri(et lu%rication studs0 /hich dip in the oil
sump and splash the oil on the lu%rication points.
*al(es Both pressure stages are pro(ided /ith lamellar (al(es0 /or4ing
/ithout riction and presenting a (er! long ser(ice lie.
:ecooler The recooler mounted to the radial (entilator o the I. and II. stages
are e?uipped as pot gal(aniCed pipe1in cooler made o steel.
Saet! e?uipment +ccording to the regulations the pressure cham%ers o %oth stages are
e?uipped /ith saet! (al(es. The saet! (al(e o the I. stage is
scre/ed into the c!linder head o the II. stage. The saet! (al(e o
stage II is mounted in the separator ater the II. stage.
The %lo/ o pressure is stamped on all the (al(es. 5or control o the
cooling a saet! use is installed in the separator. 2a(ing reached a
temperature o 12$
o
C a %oring is opened and the compressed air is
steaming out.
+utomatic 5or automatic operation the unit is e?uipped /ith an
operation electromagnetic (al(e or automatic relie and drainage o the
separator. +s a special accessor! the compressor1unit ma! %e
e?uipped /ith a temperature control instead o a saet! use0 as /ell
as /ith an oil le(el control.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
(. Commissionin# an% Opera!ional Re#'la!ions
(.) Opera!ion * Sa$e!+ Ins!r'c!ions
The compressor is %uilt according to the state o art is relia%le. 5rom the plant0 ho/e(er0 ma!
come dangers in case o that it is used inappropriatel! or not or its destinated application.
5or maintenance /or4s0 operation and repair onl! authoriCed personnel ma!%e ta4en /hich
did read the complete instruction manual including the saet! instructions prior to /or4ing on
the plant.
+ll /or4s on the compressor ma! onl! %e perormed i it is s/itched1o and currentless
condition. +ll compressed air carr!ing parts must %e pressureless.
The user has to care that the compressor is onl! in operation in uno%7ectiona%le condition.
The complete plant has to %e clean and ree rom oreign matters. Special care has to %e
ta4en that no tools lie around.
The compressor ma! onl! %e used or compression o air.
DnauthoriCed reconstructions and alterations /hich ma! inluence the sae operation o the
compressor0 are not permitted.
The compressor ma! not %e operated /ithout protection de(ice.
The saet! (al(es ma! not %e ad7usted0 onl! sealed (al(es ma! %e used. Damaged saet!
(al(es ha(e to %e replaced %! ne/ ones. Onl! authoriCed personnel is allo/ed to read7ust0
repair or seal the saet! (al(es.
(.1 Se!!in#&'p A%,ices
The compressor unit must %e installed so that the maintenance spaces as indicated in the
installation dra/ings are 4ept ree. The erection place should %e easil! accessi%le.
I the compressor assem%l! is mounted on (i%rations mounts0 no resonance rom re?uenc!
o e3citation is permitted to %e transerred in the natural re?uenc! o the (i%ration mounts to
the compressor. The natural re?uenc! o the (i%ration mounts deli(ered as standard /ith
the compressor is appro3. 1$ 2C. I an e3citation re?uenc! o the oundation near the
natural re?uenc! due to other e?uipment installed near%!0 the (i%ration mounts ha(e to %e
changed.
Installation o the compressor assem%l! /ithout (i%rations mounts is possi%le0 pro(ided there
is a suicientl! rigid oundation.
I a compressor is supplied /ithout a dri(e0 the alignment %et/een the compressor and the
dri(e has to %e perect.
The drain line o dierent compressors ma! not %e com%ined in one pipeline. The collected
moisture contains oil and must not drain untreated into the se/age /ater s!stem. The
moisture should lo/ through a pipe into a tan4 and should ater/ards %e s4illull! rec!cled
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
or %e disposed o %! a specialiCed compan!. +s accessories E.P. Sauer F Sohn oer
moisture rec!cling units0 /hich ma4e a separation o oil and /ater possi%le.
The cooling1air has to %e conducted to the cooling1air1inlet0 not to the c!linders o the compressor
8see e3ample %elo/9.
The compressor must not %e installed in a corner so that the cooling air is again induced in a short
circuit. I more compressors are running at the same time0 an installation in line must %e a(oided so
that the second compressor cannot induce the heated cooling air rom the irst compressor.
I needed0 Sauer supports !ou in the design o the room (entilation.
2ose1lines should not %e installed under tension or turned/t/isted around 8see %elo/9.
<hen installing no1return (al(es0 a minimum distance o 1 m to the compressed air outlet on the
compressor should %e o%ser(ed.
On normal compressor operation conditions0 the (al(es should not ma4e an! noises.
Decrease in pressure %et/een the compressor and the air %ottle0 due to resistance to lo/0 has to %e
ta4en into account %! setting the pressure s/itch at the air %ottle lo/er than the operational pressure
o the compressor. Other/ise0 it ma! happen that the saet! (al(e o the compressor reacts earlier
than the pressure s/itch. To ensure sae operation o the compressor0 a pressure s/itch must %e
installed at the pressure (essel 8a(oidance o pulsation9.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
The electrical connection must %e e3ecuted %! a s4illed electrician. It has to %e chec4ed /hether
current0 (oltage and re?uenc! correspond /ith the data gi(en on the t!pe plate. I the compressor is
installed in an industrial compan!0 the technical connection regulations o the local po/er suppl!
compan! ha(e to %e o%ser(edG In addition0 the regulations o DI@ *D& $1$$ and DI@ &@ '$2$4 ha(e
to %e o%ser(ed.
(." Commissionin#
The compressor is shipped /ithout oil charge. +ter unscre/ing red closing plug0 ill
cran4case /ith 10" l o %randed oil up to upper mar4 o dipstic4 in accordance /ith the oil
recommendation or Sauer compressors. Prior to initial start0 chec4 compressor or eas!
operation %! rotating cran4shat manuall!. During initial start chec4 direction o rotation
8cooling air lo/ rom an /heel to c!linder0 on the right0 /hen loo4ing at dri(ing side9.
(.( Opera!ion Ins!r'c!ions
Draining The drainage o the condensate separator is done %! the mounted (al(e. This
can either %e manuall! operated or solenoid0 according to order.
The solenoid (al(e is closed at direct on1line start 8DO-9 /hen the
compressor is started. +t stop o the compressor it is opened to ena%le a
relea(ed run1out. +t start1delta1start 8HD9 the (al(e is closed /hen s/itching
into delta1phase. The manual (al(e must %e open at the start o the
compressor. It is shut /hen the operational speed is achie(ed. +t stop o the
compressor irst the (al(e must %e opened0 the compressor is shut do/n.
(.- P'! o'! o$ ac!ion
Compressors /hich are cut1o or short periods0 should perorm a trial o at least 3$ minutes
e(er! 4 /ee4s.
I operation is interrupted up to 12 /ee4s0 additional corrosion protection is not re?uired.
5or compressors0 /here inter(als %et/een operation e3ceed 12 /ee4s0 anti1corrosion
protection is recommended. In such a case compressor oil used must %e replaced %! anti1
corrosion oil. Since the anti1corrosion oil has ade?uate running characteristics0 the
compressors can %e operated at short notice or emergencies. 5or corrosion protection o
compressor a%out to %e made inoperati(e0 proceed as ollo/s6
- :un compressor or appro3. " minutes /ithout counterpressure /ith pressure line
open to %lo/ o condensate0 i an!.
- Drain compressor oil rom cran4case.
- 5ill in appro3. 10$ l o anti1corrosion oil.
- Start compressor and run or appro3. " minutes /ithout counterpressure /ith
pressure line open0 then cut1out.
- Dnscre/ air cleaner and loosen cooler o stage I on c!linder head o stage II.
- Start compressor and slo/l! spra! 1" cm
3
o anti1corrosion oil into inta4e connection0
and appro3. 1$ cm
3
into open scre/ connection on c!linder head o stage II 8Caution0
an /heel ma! not %e co(ered9.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
- Cut1out compressor the moment oil og comes out o cooler o stage I and pressure
line.
- :einstall air cleaner and cooler.
- Drain anti1corrosion oil rom cran4case.
5or rene/ed operation0 reer to item 3.2 Commissioning.
(.. A%,ice $or opera!ion o$ !he compressor /i!h %iesel en#ine %ri,e
The compressor1unit is e?uipped /ith a centriugal clutch to guarantee an unloaded start o
the diesel engine.
The clutch is engaged at appro3. 1$$$
1
/min. a deinite po/er transmission is made rom
14$$
1
/min on.
Due to this act the speed regulating de(ice o the diesel1engine is not to %e changed.
Se!!in# !o /or01
1. Control oil le(el /ith dipstic4.
2. Open condensate outlet coc4 on separator.
3. Start motor.
4. Close condensate outlet coc4.
P'!!in# o'! o$ opera!ion1
1. Open condensate outlet coc4
2. S/itch o dri(ing motor.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
(.2 A%,ice $or a'!oma!ic opera!ion
The %ottle pressure s/itch does the control o the compressor1unit in automatic operation. It
is mounted on the compressed air reser(oir or in the compressed air pipe. <hen attaining
the prescri%ed minimum pressure 8e.g. 2$ %ar9 in the compressed air recei(er the %ottle
pressure s/itch closes its s/itching contacts. The motor is started (ia a motor s/itch gear
and the currentless open electromagnetic drainage (al(e is closed. <hen attaining the
prescri%ed ma3imum pressure 8e.g. 3$ %ar9 in the compressed air recei(er0 the pressure
s/itch opens its s/itching contacts again. B! that the motor is s/itched o (ia the motor
s/itch gear and the drainage (al(e is opened. The condensate /hich accumulate s during
operation in the separator is drained o (ia the open drainage (al(e and the compressor is
unloaded up to the non1return (al(e mounted in the compressed air recei(er during the stop
o the compressor.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
-. Main!enance
Scre/ connections "$ operating hours ater initial operation chec4 %olts and nuts in
cran4case0 c!linders0 pipelines and holders or tight seat. +ter "$
hours o operation also chec4 scre/ connections released during
maintenance 7o%s or tight seat.
-u%ricating oil During initial operation0 change oil ater "$ hours o operation0
additional oil changes ater each 1$$$ hours or operation0 %ut at least
once a !ear. Dse a t!pe o lu%e oil in accordance /ith our oil
recommendation. Chec4 the oil le(el dail!.
+ir cleaner <hen operating under normal conditions0 maintenance o air cleaner
is made e(er! 1$$$ hours %! remo(al o the element and /ashing it in
an oil1dissol(ing luid0 e.g. gasoline or 4erosene. Dpon /ashing0 %lo/
out element /ith compressed air rom inside out. Then immerse
element in clean engine oil 8S+& 2$9 and let drip o or 2$13$ minutes.
Drip trap in the separator has to %e cleaned regularl!.
*al(es +ter 2$$$ hours o operation0 chec4 (al(es o stage I and o stage II
or /ear and damage. During disassem%l! and assem%l! do not clamp
(al(es and (al(e parts into (ise. <hen cleaning the indi(idual (al(e
parts0 /hich is done %est ater irst soa4ing these parts in 4erosene0
%e sure to pre(ent an! damage to sealing suraces %! scratches and
emer! cloth. :ene/ (al(es sho/ing /ear or damage. <hen install
(al(es0 use ne/ gas4ets. The gas4et placed %et/een (al(e and
c!linder head stage II must %e rene/ed /hene(er (al(e is remo(ed.
+t periodical inter(als chec4 the saet! (al(es on the compressor %!
liting them.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
MANILA, PHILIPPINES
.. Opera!in# Tro'3les an% !heir elimina!ion
Saet! (al(e I. stage is %lo/ing o6
- The com%ined suction and deli(er!1(al(e o II.stage is not tight. Dismantle the (al(e
and chec4 it.
- Gas4et damaged %et/een c!linderhead stage II and compressor1(al(e.
- Cooler got cho4ed.
Saet! (al(e II.stage is %lo/ing o6
- The loc4 (al(e in the %ottle illing leads is closed.
- Bottle pressure s/itch is damaged or ad7usted incorrectl!. :eplace pressure s/itch
or re1ad7ust0 respecting the instruction gi(en.
- @on1return (al(e does not open at all or onl! partiall!. :eplace non1return (al(e. +
damaged non1return (al(e can also %e the possi%le reason or pressure loss in the
air %ottle at compressorIs standstill.
A!!en!ion1
- DonIt ad7ust saet! (al(es to higher pressure. :eplace deecti(e (al(es.
-oss o capacit!6
- The concentric (al(e o I.stage is not tight. Dismantle the (al(e and chec4.
- -ea4ages in the compressor tu%ing or in the %ottle illing leads0 repair lea4ages.
- Drainage (al(e not tight resp. not closed0 repair damaged drainage (al(e or replace
it. DonIt close the drainage pipelineG
- Dirt! air ilter0 clean air ilter.
- :ecooler or air pipes got cho4ed.
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INTERSHIP NAVIGATION TRAINING CENTER, INC
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2. S!ar!in# proce%'re o$ air&coole% sa,er compressor

4RIE5 INSTR6CTION 5OR THE INITIAL START O5 OPERATION1
1. The unit must not %e installed in the direct air stream o a (entilation s!stem.
2. 5ill the compressor /ith oil according to our oil recommendation up to the
upper mar4 on the dipstic4.
3. Chec4 the correct installation o connections to the surrounding plant. Chec4
especiall!
the pressuriCed air connection.
4. Chec4 i the lo/ through the non1return is in the right direction 8direction o
arro/9.
". In the drainage line o the stopped compressor no pressure must %e %uild up
%! other
units %lo/ing into the same drainage line.
'. Start the compressor o some seconds to chec4 the sense o rotation. It must
%e identical
/ith the arro/ glued to the cran4 case
). The compressor must start %! open drainage (al(e. +ter a e/ seconds the
(al(es close
and the compressor runs up against the pressure. The pressure gauges o the
stages
shall sho/ the (alues gi(en in the operation manual.
,. +ter "$ operation hours all scre/ connection at the cran4case0 c!linders0
pipes and
5asteners must %e chec4ed or tightness. +n oil change must %e e3ecuted.
4RIE5 OPERATION INSTR6CTION
1. Chec4 dail! the oil le(el. Beore lo/er the dipstic4 mar4 is reached the oil
must %e reilled
up to the upper mar4 /ith oil according to our oil recommendation.
2. The compressor must start %! open drainage (al(e. +ter a e/ seconds the
(al(es close
and the compressor runs up against the pressure.
3. Three and our stage air compressors need an intermediate drainage. This
should %e
set that the compressor is drained e(er! 1" minutes or 1" seconds.
4 Chec4 the operation noise o the non1return (al(e. During normal operation
the (al(e must not rattle.
". Chec4 i at increasing operation hours the pressure gauge indication de(iates
rom the normal (alues.
". O%ser(e the maintenance inter(als or Sauer1compressors. + shortening o
The maintenance inter(als does not impro(e the operation %eha(ior or the
lietime o the Compressor.
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MANILA, PHILIPPINES
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MANILA, PHILIPPINES
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INTERSHIP NAVIGATION TRAINING CENTER, INC
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