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Clean, compact, reliable

Systematic Progress

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SAACKE MARINE SYSTEMS:

The marine section of the SAACKE Group Your systems partner for heat generating. The unconditional reliability of a system at high sea under gale winds, the stiff breeze of global competition in shipbuilding and logistics, the protection of the ocean as our natural habitat and commercial arena – these are the challenges to be met. Maritime technology is systems technology, tried and proven under the extreme conditions of the marine environment. As a systems partner for shipyards, shipping lines and investors, SAACKE MARINE SYSTEMS conceives, plans and manufactures turnkey plants for heat generating on board ships and for offshore technology, straight through to their commissioning, maintenance and ongoing real-time optimisation. Pioneer work in the redefinition of burner-boiler compatibility of the plants manufactured at our own facilities has increased their overall economic efficiency and still left room for strict observation of current and future environment protection parameters. SAACKE MARINE SYSTEMS offers the depth of insight that comes from the wide experience of specialists, the broad span of resources of a systems manager active on a worldwide level, and the customer proximity of a globally networked service partner – all from a single source.

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One system. One partner. Solid advantages.

Applied synergy More than 70 years of reliability, with thousands of references to prove it: 100 000 firing systems including about 10 000 boilers of every type represent a wealth of engineering and project management know-how.

Water-tube boiler

The burner-boiler alignment has brought a solid improvement in performance, a drastic reduction of emission rates and a streamlined plant structure. The broad performance and product range of our burners and boilers from 1 MW to 80 MW offers a solution for any application in shipbuilding and offshore technology firing any gaseous or liquid fuel.

Rotary cup atomiser

Control cabinet

Customer proximity thanks to the short distances and open access within Europe and Asia facilitates the coordination of your project and keeps you up to date on developments. Systems partnership stands for turnkey solutions in heat generating, in other words the longterm bottom-line payoff on your investment. A main contributing factor is the ability to adapt the plant at will to different fuels and operational conditions: real-time optimisation keeping pace with the latest technology.

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New perspectives for research and development

The flame determines the design At SAACKE MARINE SYSTEMS, research and development is aimed at practical results. Its goal is the maximum productivity attainable in heat generating according to the parameters of safety, environmental protection and economic efficiency for the entire plant. Burners and boilers made at SAACKE MARINE SYSTEMS, a result of the combined research and development input of our specialists in burner and boiler technology, open new horizons for our customers in every respect. This is true for the new coordination between the flame geometry and the boiler as well as the improvement of plant conception and layout and the optimisation of interfaces with the help of real simulation of functions and processes. Innovation by SAACKE MARINE SYSTEMS - be it single components or revolutionary comprehensive solutions - is no surprise to our customers. It is progress they can count on, to the decimal point.

Continuous network exchange of know-how among specialists sharing a common engineering software enhances the collected expertise of the teams.

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Cleaner, lighter, more compact

New solutions are in the detail The flame-boiler synchronisation aimed at optimal flame geometry results both in cleaner combustion and in more freedom with regard to combustion chamber dimensions, to the benefit of shipbuilding and offshore technology: less bulk, less weight and lower emission rates. First-rate engineering and the power of innovation have set standards for clean combustion with maximum efficiency rates, high reliability and straightforward burner servicing. This applies for all liquid and gaseous fuels including heavy oil and sludge. Stress test and real simulation. From the first draft on, the latest in sophisticated software is the clue to our success – saving time, effort and expense, to the benefit of our customers. Innovations with a scientific background from SAACKE MARINE SYSTEMS: revolutionary, tested under extreme conditions and founded on experience. Modularity from A to Z is the clue to the adaptability, versatility and the real-time optimisation options of our plants. Modularity is not only fundamental for the design and production of burner and boiler systems, but also vital for example for the control system, enabling easy installation in any given systems periphery.

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There is only one way:

Safety at sea Oil, gas, fire, steam and pressure ... safeguarding human life as well as our marine habitat is crucial to maritime heat generating, as is absolute plant reliability. A defect or a failure often has unforeseeable consequences. System redundancy, ease of operation, diligence in the manufacturing process of our burners and boilers to the point of weld seam x-rays are just as essential here as uninterrupted systems monitoring, precise error diagnosis and efficient troubleshooting. Where heat generating is concerned, safety means systems management on a high level - and this we guarantee. There is no room for mistakes at sea.

Innovation for highest demands: Our rotary cup atomiser SKV-A.

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Fail-safe control

Everything counts

Safe and simple A benchmark in firing fiplant automation from SAACKE R&D, nally creates an ethernet connection between the control system and the combustion process that is secure. All of its sensors and actors are fail-safe bus-connected. The HMI (Human Machine Interface) touchscreen is the new convenient way to operate, parameterise and optimise your process. System control

Fail Safe Motor (FSM) Worldwide, the only precision servomotor control via a safe ethernet connection – with a wide range of diagnosis functions. Fail Safe Control (FSC) The FSC – a fail-safe PLC-based automatic firing sequence controller with electronic compound control that adapts to any firing system. For basic parameters (burner model, fuel, safety times…) and complex operations such as multi-fuel mode or master/slave boiler sequence control. Minimum downtimes – maximum plant availability The maintenance assistant notifies you immediately which plant components need to be inspected, serviced or replaced. The initial fault message system pinpoints the cause in a flash with an e-mail option for important data and power failure protection to safeguard your archives. Tele Support & Service Plug in at any point on the globe and let the Head Office in Bremen log for on-the-spot remote diagnosis or troubleshooting.

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Environmental protection beyond current regulations

Lower emission rates protect your investments Protection of the maritime environment defines the commitment of our systems to quality and its enforcement will be even more stringent in the future. Designed in compliance with the much stricter environmental regulations onshore, our offshore heat generating plants are ready to meet future ecological requirements for shipbuilding and offshore technology: Clean combustion from optimal flame geometry, Low-NOx emission rates are standard features of all of our plants right now. Either they are already geared to stricter regulations and norms or will minimise the expenditures involved. This protects our environment and safeguards your investment – from day one, and for years to come.

More environmental protection with stricter regulations will define our future – both on land and at sea.

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Future environmental standards will demand not only clean combustion but also precision, diligence and stringent quality control in plant manufacturing and assembly.

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High environmental standards and adaptability

Founded on the future As a pioneer in onshore burner technology where much stricter environmental laws are in force, SAACKE MARINE SYSTEMS makes experienced engineering available to the maritime heat generating market. Plants manufactured by SAACKE MARINE SYSTEMS already comply today with upcoming regulations on the protection of the marine environment. Burner manufacturing SAACKE Bremen (Germany)

Reliability and a plant service life of 30 years and more can be put to your full advantage. Changes in the peripherals do not entail exchanging or replacing complete systems. The high ecological standards and modular design of our heat generating plants permit continuous lowcost adaptation to ecological and technological progress. Plants by SAACKE MARINE SYSTEMS do not “age”.

Boiler manufacturing SAACKE Zagreb (Croatia)

The responsibility of SAACKE MARINE SYSTEMS for the entire heat generating concept ensures a homogenisation of quality, clockwork scheduling and optimised resource management – all to the benefit of the customer.

Boiler manufacturing SAACKE Qingdao (P.R. China)

Competence from years of tradition in plant engineering guarantees state of the art project management, production and maintenance worldwide.

Delivery

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Burners, boilers and systems from our own production facilities

Customisation puts you a step ahead F.P.S.O., Cruise Liners, Container Ships, LNG Carrier and Tanker Ships – heat generating plants from SAACKE MARINE SYSTEMS are customised systems in line with the high quality requirements of our own manufacturing facilities. Certified in compliance with all of the international norms, backed by worldwide references, our plants are designed precisely according to your specifications, manufactured and assembled as a highly efficient unit to fulfil the given task completely, reliably and safely. We have made a point of designing the burner, the boiler, the control and pipe-line systems as components to create an 'intelligent' modular system. Our concept of customisation – precisely tuned to current application specifications – leaves room at the same time for adaptation and optimisation, to keep abreast of changing market, environmental and technological requirements. Flexibility by diversity and customisation in manufacturing is systems quality the way we understand it.

Only by manufacturing the entire system at our own facilities we can guarantee the comprehensive systems quality you need.

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An example of clean-room quality at SAACKE.

Internationally certified quality.

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Tried and proven, worldwide

Quality at its best Burners, boilers and control systems made by SAACKE MARINE SYSTEMS represent experience, first-rate engineering and maximum accuracy in manufacturing and assembly, up to the finishing touches, supervised and improved continuously according to the standards defined by today’s leader in technology. Diligence

Precision

A meticulous delegation of specific tasks optimises the process from day one. The timeconsuming �relay race� from planner to designer to production scheduling and procurement has been replaced by a hand-in-hand, simultaneous, synchronised exercise in perfected burner and boiler engineering. Planning and design work are reduced to the essentials by combining standardised components and harmonising the interfaces between burners, boilers and control systems. Certification of every process, burner and boiler according to ISO 9001.

Approval

Availability

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Excellence in practice on board

Passenger ships SAACKE has been equipping passenger ships for over half a century. Every major shipping line has our systems on board. Coral Princess, Princess Cruises Burner: 2 x DDZ 10/400 Steam atomising burner Boiler: 2 x KLN /VIC Oil fired boiler 13 t/h steam output Boiler: 2 x KIP/PCK Exhaust gas economiser 5.4 t/h steam output

Queen Mary 2, Cunard Burner: 2 x DDZ 10/400 Steam atomising burner Boiler: 2 x KLN / VIC Oil fired boiler 16 t/h steam output

Pont Aven, Brittany Ferries Burner: 2 x SKV 40 Rotary cup burner Boiler: 2 x KLN / VM Oil fired boiler 5 t/h steam output Boiler: 4 x KIP / PCK Exhaust gas economiser 1.5 t/h steam output

SAACKE boiler-burner systems have proven to meet the high standards in passenger comfort in demand for modern cruise vessels from the Caribbean to the Arctic. Owners and operators of cruise liners have learned to appreciate the quality in performance and reliability of our steam generation plants – low in maintenance, yet always a step ahead of national and international environmental regulations thanks to options such as Low NOx, fuel oil viscosity control and water injection for minimum particle emissions.

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Excellence in practice on board

Container ships The comparatively low steam consumption on board container ships makes the SAACKE composite boiler together with the SAACKE rotary cup burner the ideal solution for these applications. 2474 TEU Burner: 1x SKV 30 Rotary cup burner Boiler: 1x K / KD Composite boiler 3 t/h oil fired section, 3 t/h exhaust gas section

4100 TEU Burner : 1x SKV 40 Rotary cup burner Boiler: 1x KLN / VM Oil fired boiler 4 t/ h steam output Boiler: 1x KIP/DV Exhaust gas boiler 3.0 t/ h steam output

2200 TEU Burner: 1 x SKV 10 Rotary cup burner Boiler: 1 x CBKG Composite boiler 1.8 t/h oil fired section, 2.3 t /h exhaust gas section

Either horizontal (CBKG) or vertical (K/KD), the SAACKE composite boiler is easy to accommodate. At sea it utilises the waste heat from the main engine, while the SAACKE burner unit cuts in to maintain the steam production when the main engine is not running. The SAACKE composite boiler system is designed for fully automatic operation with modulating burner load control depending on the boiler steam pressure.

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Excellence in practice on board

Tankers The steam demand on board a tanker depends on its engineering. Whatever the requirements, there is a SAACKE boiler system to fulfil them. Suezmax Oil Tanker Burner: 2 x DDZ 12/500, Steam atomising burner Burner: 1 x SKVJ 15, Rotary cup burner Boiler: 2 x KLN /VIC Oil fired boiler 35t/h steam output Boiler: 1 x K/KD Composite boiler 1.8 t/h oil fired part, 1.4 t/h exhaust gas part steam output Product Tanker Burner: 1 x SKV 100, Rotary cup burner Burner: 1 x SKVJ 15, Rotary cup burner Boiler: 1 x KLN / VIC Oil fired boiler 12 t/h steam output Boiler: 1 x K/KD Composite boiler 1.5 t/ h oil fired part, 1.2 t/h exhaust gas part steam output Oil Tanker Boiler: 1 x KLN / VIC Oil fired boiler 25 t/h steam output Boiler: 1 x KIP / OCK Exhaust gas economiser 1.5 t/h steam output

Our twin KLN/VIC boiler system with a capacity of up to 2 x 40 t/h is tailor-made for tankers with a high steam demand, featuring burners with a turn-down ratio of up to 1:20 with a low oxygen content for inert gas generation. The system is designed for fully automatic loaddependent master-slave operation with operator's interfaces. A single boiler in the 5 to 40 t/h capacity range will satisfy the steam demand of a medium-sized product or chemical tanker. For general heating purposes a composite boiler is supplied that utilises the exhaust gas from the main engine.

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Excellence in practice on board

Miscellaneous ships The number of ships in other categories outfitted with our boiler systems is growing daily. Here is just a random selection. Bulk Carrier Burner: 1 x SKV 20 Rotary cup burner Boiler: 1 x KLN / VM Oil fired boiler 2 t/h steam output Boiler: 1 x KIP/ L Exhaust gas economiser 1.5 t/ h steam output

Reefer Burner: 1 x SKV 15 Rotary cup burner Boiler: 1 x KLN / VM Oil fired boiler 1.7 t/h steam output Boiler: 1 x KIP / OC Exhaust gas economiser 1.3 t/ h steam output

Car Carrier Burner: 1 x SKVJ 15 Rotary cup burner Boiler: 1 x K /KD Composite boiler 2 t/h oil fired part, 1 t / h exhaust gas part steam output

Both composite boilers and separate systems with an oil-fired and an exhaust gas boiler can be found on ships like these, depending on the service required from them – but also on how the owner prefers to equip his vessel. Either way, a SAACKE system reflects the same wealth of know-how such as permanent burner stand-by function, automatic burner start if the steam from waste heat at sea is not sufficient, and automatic periodic burner start during the voyage to maintain the oil viscosity and keep the burner ready to fire when needed.

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Excellence in practice on board

F.P.S.O. – turnkey solutions One-stop procurement, from the concept to the trial run. The demand for F.P.S.O. facilities is filled by both newbuildings and conversions. SAACKE is the primary boiler systems provider for both requirements from start to finish. The same team of experts pursues the project from the initial idea straight through to the final commissioning and trial run. Clockwork coordination ensures that the turnkey system is designed precisely for your specific application at top speed. The result is a fail-safe boiler management system, meticulously controlled combustion and the high availability rate for which SAACKE has been renowned for generations. Boiler upgrades for firing gas in F.P.S.O. conversions. Consult SAACKE for an inspection of your existing plant and advice on the scope of replacement including an expert boiler recalculation. Boiler engineering and manufacturing for newbuildings. With our experience in the marine engineering sector, our project team will tailor the standard boiler design to your specific requirements. Your boiler will be manufactured by SAACKE, at SAACKE, to your specifications and to any class requirements. Dual-fuel burner engineering and manufacturing including the fuel oil and fuel gas supply units. Control system engineering, the key to the success of your F.P.S.O. project. SAACKE puts your plant philosophy first as the operator or owner of the facility to make sure your daily operations are patterned to your preferences. Support for your own installation team as a cost-saving alternative, to the extent you determine and wherever you need it. Commissioning by a SAACKE engineer to guarantee optimum performance.

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Excellence in practice on board

LNG carriers The real solution to alternative propulsion: the GCU

ALSTOM Marine LNGC (Yves Guillotin)

Boil off gas (BOG) is usually utilised for propulsion in a conventional boiler-steam turbine combination. The alternatives on the drawing board are either dual-fuel engines or a combination of a two-stroke engine and a reliquefaction plant. However, both of these require a redundant system for safe combustion of the BOG. The turning point has come from SAACKE: the Gas Combustion Unit (GCU). Here are its highlights: Compact design based on to SAACKE Swirl Combustion Technology (SSCT). The GCU is small enough to be installed in the stack leaving extra space in the engine room for the propulsion equipment only.

ALSTOM Marine, back view of ship funnel with installed GCU

Safe and stable BOG combustion with SSCT, during gas freeing down to 5 MJ/Nm3 without a support fuel – and for gas freeing from 5 MJ/Nm3 down to 0 in dual-fuel mode with a minimum of support fuel. Low NOx for better than perfect compliance with emission rules. The flue gas CO concentration is virtually negligible. Quick-start mode with a start-up sequence of only a few minutes in case a primary BOG consumer fails causing a sudden increase in the LNG tank pressure.

GCU 300, M32-Project

Stand-by eco mode for quick start-ups with minimum electric power consumption. Closed combustion chamber (like that of a boiler) to ensure uninterrupted operation even under the roughest conditions at sea. Vent gas burning from a reliquefaction plant as standard equipment.

GCU 300, M32-Project incl. swirl-burner

No salt water corrosion of the unit since the flue gas is cooled by air instead. This also solves the problem with salt water vaporisation and precipitation in port.

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Fast, global, networked:

Service is more than meets the eye Service stations in 20 countries worldwide, an additional 70 international contact offices, support and remote diagnosis, spare parts delivery with 24-hour service, repairs and replacements around the clock... We are competent, we are fast, and we are there when you need us. Supported by a tight-knit worldwide service network and extensive resources in maintenance, repair and spare parts logistics, we guarantee trouble-free operation of your heat generating system long after its commissioning. Our customers all over the world can rely on fast service where repair and replacement of our systems components is concerned. Depending on the individual agreement, a service partnership with SAACKE MARINE SYSTEMS includes maintenance and realtime optimisation of your plant, training for your crew, safety inspections or complete systems management by our specialists. In line with our plant philosophy, our service offers a modular system of options to choose from at any time. We are geared to one aim: to make sure your heat generating plant functions well for many years to come – and stays economic, eco-friendly and reliable!

Our extensive service network increases the availability of your plant.

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Good reasons for a systems partnership

Customer proximity regardless of distance Easy commissioning is a distinctive feature of our plants and part of our turnkey deliveries. Guarantees tuned to your specific type of plant are a good basis for a systems partnership. Fair treatment in finding a rapid solution to the problem during our guarantee period is how we define customer service. Our extensive service network acts fast, reduces transport and downtime costs and increases the availability of your heat generating plants. By training your crew 'on the job' as well, we open the way for do-it-yourself repairs and cut the expense in time lost waiting for outside service staff. Continuous advanced qualification explains our service specialists' high competence in all fields of heat generating. Robust and easy-to-service plants reduce maintenance expenses. They are the answer to the drastic downsizing in crews in general and the resulting increase in the demands placed on each member on board. Comprehensive documentation of every plant process and each measure which keeps it running, as well as detailed descriptions of every systems component and function are the key to easy operation, monitoring, maintenance and repair.

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SAACKE ROSSPLET S.A., ARGENTINA Phone + 54 - 11 - 49 11 14 80, Fax + 54 - 11 - 49 12 30 41 SAACKE AUSTRALIA Pty. Ltd., AUSTRALIA Phone + 61 - 2 - 96 36 77 77, Fax + 61 - 2 - 96 31 34 13 SAACKE Ges.m.b.H., AUSTRIA Phone + 43 - 1 - 86 93 345, Fax + 43 - 1 - 86 93 34 530 SAACKE Belux, BELGIUM Phone + 32 - 3 - 88 61 100, Fax + 32 - 3 - 88 61 226 SAACKE do Brazil, BRAZIL Phone + 55 - 11 - 34 43 70 06, Fax + 55 - 11 - 34 43 66 01 SAACKE S.A.R.L., FRANCE Phone + 33 - 1 - 48 48 20 54, Fax + 33 - 1 - 48 47 73 66 SAACKE Ltd., GREAT BRITAIN Phone + 44 - 23 - 92 38 31 11, Fax + 44 - 23 - 92 32 71 20 SAACKE Baghdad Representative Office, IRAQ Phone +964 - 1 - 5 52 16 42, Fax +964 - 1 - 7 74 74 12 SAACKE JAPAN TRATEC Ltd., JAPAN Phone + 81 - 3 - 33 39 12 11, Fax + 81 - 3 - 33 39 75 77

SAACKE MARINE SYSTEMS SAACKE Korea Co., Ltd., KOREA Phone + 82 - 51 - 465 7661, Fax + 82 - 51 - 465 7663 SAACKE Benelux, NETHERLANDS Phone + 31 - 33 - 4 33 00 14, Fax + 31 - 33 - 4 33 00 16 SAACKE Polska Sp. z o.o., POLAND Phone + 48 - 71 - 36 81 865, Fax + 48 - 71 - 36 08 929 SAACKE Energy Systems (Shanghai) Co., Ltd., PR CHINA Shanghai Office Phone + 86 - 21 - 63 60 34 89, Fax + 86 - 21 - 63 60 34 33

TPK NOVA d.o.o. ˇ Zitnjak b.b. · 10000 Zagreb CROATIA Phone + 385 - 1 - 24 06 418 Fax + 385 - 1 - 24 07 016 eMail sales@tpk-nova.hr

SAACKE QINGDAO MARINE BOILER CO., LTD.

SAACKE Moskau Representative Office, RUSSIA Phone + 7 - 095 - 7 89 31 17, Fax + 7 - 095 - 9 80 99 20 SAACKE Belgrade Representative Office, SERBIA AND MONTENEGRO Phone + 381 - 11 - 301 73 35, Fax + 381 - 11 - 301 73 36 SAACKE South Africa (Pty) Ltd., SOUTH AFRICA Phone + 27 - 21 - 94 53 806, Fax + 27 - 21 - 94 53 808 SAACKE ESPAÑA, SPAIN Phone + 34 - 976 - 25 87 51, Fax + 34 - 976 - 25 87 52 SAACKE AG, SWITZERLAND Phone + 41 - 1 - 82 15 656, Fax + 41 - 1 - 82 15 644 SAACKE TURKEY LTD. Sti, TURKEY Phone + 90 - 216 - 34 93 112 , Fax + 90 - 216 - 33 03 778 Our Service Partner SCANDINAVIAN BOILER SERVICE Europe: Phone + 45 - 70 - 27 10 00, Fax +45 - 70 - 27 10 01 Asia: Phone + 65 - 67 67-0200, Fax +65 - 63 64-03 00 United States: Phone +1 - 954-763-73 75, Fax +1 - 954-766-26 24

West of Kunlunshan Road Machinery Industry Park Qingdao Development Area 266510 Qingdao P.R. China Phone + 86 - 532 - 8 60 59 500 Fax + 86 - 532 - 8 68 37 828 eMail contact@saackeqingdao.com

SAACKE GmbH & Co. KG Südweststrasse 13 · 28237 Bremen GERMANY Phone + 49 - 421 - 64 95 0 Fax + 49 - 421 - 64 95 363 eMail marine@saacke.de

MARINE SYSTEMS www.saacke-marine-systems.com

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© SAACKE 09/05

SAACKE Energy Systems (Shanghai) Co., Ltd., PR CHINA ˇ Beijing Office Phone + 86 - 10 - 85 27 60 76, Fax + 86 - 10 - 85 27 60 78

SAACKE - System_Progress  

Clean, compact, reliable For more details visit www.marinemegastore.com or call 0871 8732404 1 For more details visit www.marinemegastore.co...

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