ShipsPropulsion shaft and power generation solutions for Ship Owners, Ship Managers, Ship Designers and Shipyards
SCHAAF Solutions – A peace of mind technology!
Innovative solutionsfor the ship industryShaft and drive connections, oil press fits, assembly tools for engine and gear construction in up to 4000 bar hydraulic high-pressure technology
Hydraulic pretensioning since 1954 SCHAAF GmbH & Co. KG deals with the
development and manufacturing of hydraulic
high-pressure tools and hydraulic
high-pressure components, specifically
constructed to meet the requirements of the
ship industry and further application areas.
Due to our “in house” product development
department and onsite three shift manufacture,
we operate an almost 100 % vertical business
structure.
Thanks to a comprehensive and detailed
quality policy we are able to meet exacting
product requirements expressed by our
customers.
Examples of certificates
Internationally / multilingual for you.
Staff:
Internet:
Presentations:
Animations:
DVD-Interactive:
Represent. countries:
SCHAAF TaicangSince 2011, SCHAAF operations have included an additional 1500 sqm
manufacturing facility located in Taicang (close to Shanghai). Initially
starting with a Shanghai sales office in 2007, SCHAAF Taicang is now a fully
functional sales and manufacturing part of SCHAAF in China, to the same
exacting quality policies as held in Erkelenz, Germany. Product design and
development will continue to remain at the Erkelenz head office whilst both
sites operate in accordance with DIN ISO 9001 quality standards. A further
extension of the production area and distribution network is again in the
planning stage.
SCHAAF worldwideInternational production and installation
Quality ManagementTechnical SalesResearch & DevelopmentProductionCommercial departmentPurchasingITElectrical constructionAssembly
Germany China Global
100% positive locking in the flange bores plus frictional connection between flanges with guaranteed dismounting and remounting
ExpaTen
ExpaTen – Safety and cost reductionDue to patented technology within the ExpaTen design, the
radial expansion and axial pretensioning achieved, guarantees
a 100% form and friction fit. High torque values can then
be transferred via the coupling whilst remaining completely
free from backlash. ExpaTen Bolts have revolutionised the
removable flange connection of drive shafts, as a result of high
pressure hydraulic technology, improving safety and giving
recognised time and cost reductions. ExpaTen installation and
removal is guaranteed and can be done within 10 – 15 minutes
per bolt.
Reusable after removal, again and again – no sparebolts required
No delays to docking schedule, due the bolts seized in flange holes
Zero damage after removal, thereforce fully reusable for life of vessel
100% positive locking and frictional connection after installation, no slipping between the flanges
Simple and quick installation and removal of ExpaTen even after years of use
Ensures torsionally and structurally rigid connection even with sudden changes in the rotational speed or
direction of the propulsion shaft
High torque transmission, completely free from backlash
Tolerance for mounting is 0.05 to 0.2 % of the bore diameter – Increased clearance conditions for bolt installations
Simple machining of the flange holes is sufficient
Additional standard bolts can be tightened with the same Bolt Tensioner
Meets all Classification requirements
Following sea trials with shaft misalignment can be quickly and safely corrected without damage
Consistent radial and axial loads retained for all bolts on entire coupling, ensuring
no coupling slippage or bolt fatigue
No freezing required to achieve a shrink fit, improving worker safety and saving installation time
Easy installation at couplings incorporating a ‘spacer’ or additional flanges
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Traditional reamer bolts almost always
require re-working of the holes, therefore
the sleeve of the ExpaTen assembly can
be supplied in an oversize condition. The
oversize can be machined on site to give the
correct clearance condition.
Expa = Expansion = 100% positive locking in the flange boreTen = Tension = frictional connection for the joint
ExpaTen 2
ExpaTen ExpaTen with SCHAAF Bolt
Tensioner (SSV) up to 4000 bar
hydraulic pressure
Simple and quick installation and
removal of ExpaTen even after years
of use
Reusable after removal, again and
again – no sparebolts required
ExpaTen 2Ideal flange connection for misaligned flange
bores and / or unequal bore diameters
Inner bores which are exactly centric
to another
Maximum misalignment of 2 mm
Different bore diameters in the flanges
Different diameters and misalignment of the
bores in the flanges
ExpaBoltExpaBolt for flange-component-connection
Full expansion for press fitting
Free from backlash
OvermetalProviding +2mm of oversized
outer diameter of the sleeve
Allows the sleeve to be re-worked on site
to fit with the rebored hole diameters of the
flange connection holes
Overmetal
SCHAAF ExpaTen Bolts provide 5 times higher safety
than standard “friction” bolts.
Shaft and axle connection with removable, two-piece Hydraulic Nut and two-piece SafeLoc element
GripLoc
GripLoc – Powerful and safeThe GripLoc coupling system is capable of safely transferring
high forces (torque and axial) yet requiring minimal space for
installation or withdrawal, without the need of forged flanges
on the shafts. The system is as quick and easy to install as it
is to disassemble, even after longterm use. GripLoc operates
according to the principle of a radial shrinkage connection,
however overcoming the many technical challenges where
non-SCHAAF products often fail.
Made of high strength steel GripLoc, consists of an inner ‘Grip’
sleeve with conical ‘Outer Diameter’ and an outer ‘Loc’ sleeve
with a conical ‘Inner Diameter’. Using a split or integrated
hydraulic nut, the outer sleeve passes over the inner sleeve’s
conical ‘OD’ supported by oil injection channels. At the correct
position, guided by a SafeLoc element, the outer sleeve is
allowed to contract onto the inner sleeve ‘gripping and locking’
both connecting shafts together making the shaft ready for
operation.
Patented GripLoc sliding-on procedures for damage-free interference fit assembly
GripLoc can be removed simply and quickly even after years of use – again and again free from damage
High torque transmission, completely free from backlash
Time saving on assembly and disassembly
Removability is always ensured if replacement of defective Hydraulic Nut seal is ever required
Separate, removable Hydraulic Nut – that is used as a transferable tool for all same coupling types (PG 35, PG 36)
Maximum torque transfer even in minimum installation space thanks to SCHAAF friction increase design engineering
Torsionally and structurally rigid connection even with
sudden changes in the rotational speed, torque or direction of rotation
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Due to shrinkage and expansion of the conical sleeves the following advantages are given:
Can utilise a two piece hydraulic nut as a transferable tool for both cost and weight saving.
Removes coupling hole alignment issues.
Leaves the shaft free from damage and surface wear after removal.
Offers easy and flexibility of shaft removal for bearing inspection or tailshaft removal.
Easy operation and activation using one source of hydraulic pressure.
Consistent radial clamping force over entire coupling due to outer sleeve design profile.
A lifetime solution to known coupling bolt issues with a performance guarantee.
Patented GripLoc sliding-on procedures for damage-free interference fit assembly
GripLoc can be removed simply and quickly even after years of use – again and again free from damage
High torque transmission, completely free from backlash
Time saving on assembly and disassembly
Removability is always ensured if replacement of defective Hydraulic Nut seal is ever required
Separate, removable Hydraulic Nut – that is used as a transferable tool for all same coupling types (PG 35, PG 36)
Maximum torque transfer even in minimum installation space thanks to SCHAAF friction increase design engineering
Torsionally and structurally rigid connection even with
sudden changes in the rotational speed, torque or direction of rotation
PG 35 - 39 for individual solutions
GripLoc The different GripLoc characteristics and advantages of each design can be
combined with each other. So for example GripLoc can be built integrated
together with the SafeLoc mechanism in a removable Hydraulic Nut. An optimal
solution is therefore guaranteed for each application.
GripLoc PG 35 Shaft and axle connection with
removable, two-piece Hydraulic Nut
and two-piece SafeLoc element
GripLoc PG 36Shaft and axle connection with
removable, two-piece Hydraulic Nut
and flow caps
GripLoc PG 37Solidly fixed Hydraulic Nut for fast
clamping connection with SafeLoc
element screwed on
GripLoc PG 38Solidly fixed Hydraulic Nut for fast
clamping connection with SafeLoc
integrated in the Hydraulic Nut
Removable Hydraulic Nut
Removable SafeLoc
Removable Hydraulic Nut
Flow caps
Solidly fixed SafeLoc
Solidly fixed Hydraulic Nut
Solidly fixed SafeLoc
Solidly fixed Hydraulic Nut
SafeLoc in the Hydraulic Nut
Combining possibilitiesAll type of GripLoc coupling are
also available with flange and
other application requirements.
Robust, durable and lightweight mode of construction
Ready for immediate use, fully assembled and oil filled
All parts sealed and leakage free from –30 °C to +100 °C
Purely axial pressure force, independent of stroke
Uniform distribution of pressure forces
No torsion under load (no thread wear)
Wide choice of Hydraulic Nut sizes and designs
Several Hydraulic Nuts can also be operated uniformly due to the pressure build-up
Repeat accuracy even after a long period of use
Simple and easy to maintain
Treated surfaces
Special designs of any type available upon request
The Hydraulic Nut for mounting and dismantling oil-pressure mountings and roller bearings
Oil press fit
During the oil press fitting of a propeller or rudder assembly on
a ship, the intelligent control module in the SCHAAF oil press
fit system, constantly monitors and controls both the axial and
radial pressure values for each circuit. Up to 4000 bar can be
developed and distributed for the radial pressure circuit to
expand the oil injection hub and up to 700 bar pressure is fed
to the hydraulic nut by the axial pressure circuit for the push up.
By accurately monitoring and intelligently managing to target
values of pressure, time, distance and displacement on both
hydraulic circuits the hub reaches the target push up position.
Whilst remaining in position, the control module manages
both circuit pressures again, so that the hub contracts onto
the stock, or shaft, giving a perfectly positioned ‘Press fit’. In
addition to the ease and time saving advantages of operating
a single complete system, the SCHAAF oil press fit, is robust,
compact, maintenance free and designed for industrial use.
Ultimately proving itself ‘over and over’ through quality and
reliability, giving a perfect propeller or rudder installation every
time.
SCHAAF raises the world standards for oil press fit equipment, by offering improved
technology to work with ultra high hydraulic pressures. The SCHAAF STG provides a
trouble free 100% system solution incorporating hydraulic nuts, pumps, hoses and other
accessories, for all fully automated and documented installation.
4000 bar reliable Hydraulic
pump for oil press fit.
Individual tool sets for mounting large 2- and 4-stroke engines, propellers, rudders and much more
Tool setsIn addition to a number of standardized Bolt Tensioners and Hydraulic Nuts, SCHAAF has already
delivered thousands of customized axial Bolt Tensioners. The Design on Demand CAD system allows
us to realize customer solutions very quickly. All Bolt Tensioners and Hydraulic Nuts represent a 100%
system solution with SCHAAF’s accessories such as high-pressure hoses and high-pressure generators.
Saving of timeBolt Tensioners (SSV) and Hydraulic Nuts (HM) will
dramatically save the time required for tensioning applications.
This effect increases for higher tensioning forces, larger bolt
thread diameters and also the installation of several SCHAAF
SSV or HM. It is no longer necessary to apply large torque
by hand. There is a number of handling features available,
designed to make work even more easier with SCHAAF SSV
and HM.
Construction
Single stage, “large” outer diameter, small installation height
Multi-stage, small outer diameter, “large” installation height
Threads to match all screws to be pre-tensioned
All thread types, all thread sizes, all standards
Stroke limiting device
Mechanical stop (up to full operating power)
Excess stroke valve (hydraulic limited stroke through internal
pressure bleeding)
Surface treatment
Gun metal finished, blackened, varnished, chemically nickel-plated,
as per customer’s specification
Connector variations
Various thread sizes and types, axial and / or radial connecting, screw-type
connector, quick coupling nipple, rotary connection, serial connections
4000 bar reliable Hydraulic
pump for oil press fit.
Hand Lever Pumps, High-pressure units and electro-hydraulic control systems up to 4000 bar
Pumps and units
HP 3000-HT Two-stage hand lever pump for pressures up to 3000 bar,
completely assembled and ready for immediate use
HDL 1000-4000Air-Hydraulic Pumps ready for immediate use
at hydraulic pressures up to 4000 bar
HDE 3000-BKElectrohydraulic high-pressure unit for up to 3000 bar
in compact design
STG 4000-2KElectro-hydraulic two-circuit high-pressure automatic
control system for fully automatic oil press fits
MDSMounting Documentation System for control and monitoring
of the axial, hydraulic bolt-tightening process
All pumps and power units available in various models.
HP 3000-HT HDL 1000-4000 HDE 3000-BK STG 4000-2K MDS
Geometric volume / Conveying performance:
Step 1 approx. up to 30 barStep 2 up to 3000 bar
1000 - 2500 bar1.0 cm³ / stroke
1600 - 4000 bar 2.0 cm³ / stroke
0 - 1600 bar 0 - 3000 bar< 700 bar – 0.43 l/min> 700 bar – 0.085 l/min
0 - 700 bar 0 - 4000 bar
0 - 4000 bar < 700 bar – 2.3 l/min> 700 bar – 0.5 l/min
Safety valve: Factory set approx. to max. hydraulic pressure
Factory set approx. to max. hydraulic pressure
Factory set approx. to max. hydraulic pressure
Factory set approx. to max. hydraulic pressure
Oil-level indicator: Readable on the outside Readable on the outside Inspection glasses / Float switch
Inspection glasses / Float switch
Pressure connection: According to type key Broadest range of variations
According to type keyBroadest range of variations
According to type key Broadest range of variations
According to type key Broadest range of variations
According to type key Broadest range of variations
Tank content: 2.1 litre 6 litre 2.5 litre 33 litre 33 litre
Useable volume: 2.0 litre 5 litre 1.5 litre 23 litre 23 litre
Pump body / Set-up: Burnished, high-strength tempered steel
Service-friendly construction in compact frame
Service-friendly construction in mobile frame
Service-friendly construction in mobile housing
Service-friendly construction in mobile housing
Weight 17 kg Approx. 34 kg (incl. distributor and pressure gauge)
60 kg Approx. 240 kg Approx. 240 kg
Quick-locking coupling nipple
Quick-locking coupling socket Adapter High-pressure
hoseadapterRotatable
elbow connectorBlanking plug
Thread: CVN15 G ¼“ IG CVK15 G ¼“ IG G ¼“ AG / G ¼“ AG G ¼“ AG / M14x1,5 AG 60° G ¼“ AG / CVN16 G ¼“ with cutting edge
Thread: CVN16 G ¼“ IG CVK16 G ¼“ IG G ¼“ AG / G ¼“ AG G ¼“ AG / M14x1,5 AG 60° G ¼“ AG / CVN16 G ¼“ with cutting edge
Thread: CVN25-2 G¼“ IG CVK25-2 G¼“ IG G¼“ AG BSP120° G¼“ BSP 120° / G¼“ AG 60° G ¼“ BSP 120° AG / CVN25-2 G ¼“ BSP 120°
Thread: SVN30/40 M16x1,5 IG SVK30/40 M16x1,5 IGM16x1,5 AG 58° / M16x1,5 AG 58°
M16x1,5 AG 58° / G¼“ AG 60°
M16x1,5 AG / SVN30 M16x1,5 with cone 58°
Hydraulic High Pressure Accessories which are customized to each application
Accessories
SCHAAF offers all hydraulic high pressure accessories which are required
for the operating and handling of hydraulic devices.
Gauges
Scale: 0 - 1000 bar, Double (bar / MPa) 0-1600 bar, Double (bar / MPa) 0-2500 bar, Double (bar / MPa) 0-3000 bar, Double (bar / MPa)
Class / Filling: 1,0 / Glycerine 1,0 /Glycerine 86,5 %
Hoses A0562 A0654 A0647
High pressure hoses and tubesAll items are available individually.
Max. / Test / Bursting pressure for item 1: 1800 bar / 2700 bar / 4500 bar 3000 bar / 4650 bar / 6200 bar 3000 bar / 3750 bar / 6250 bar
Inner tube: POM
Pressure jacket: 4 spiralled layers of corrosion-proof high tensile steel
6 spiralled layers of corrosion-proof high tensile steel
Outer sheath / Protective hose: PA, Nylon / PVC
In- /Outside diam. (incl. protective hose) 5.0 mm / 11.6 mm (18.0 mm) 5.0 mm / 13.0 mm (22.0 mm)
Weight: 0.29 kg/m 0.43 kg/m
Item 1: High-pressure hose
Item 2: Adapter G¼“ AG / M14x1.5 AG 60° Adapter G¼“ BSP 120° AG / G¼“ AG 60° Adapter M16x1.5 AG 58° DK / G¼“ AG 60°
Item 3: Quick-release coupling sleeve CVK16 G¼“ IG Quick-release coupling sleeve CVK25-2 G¼“ IG Quick-release coupling sleeve SVK30 M16x1.5 IG
Item 4: Quick-release coupling nipple CVN16 G¼“ IG Quick-release coupling nipple CVN25-2 G¼“ IG Quick-release coupling nipple SVN30 M16x1.5 IG
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M16
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M16
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M16
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M16
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AG
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... and state of Asian test equipment, replicas...
When saving money and no quality philosophy...
In Asia and many other countries we regularly see examples
of low quality steel and materials being used which would
definitely fail the German DIN standards that we use. We
see examples of materials which have no bursting strength,
cracks & faults present, low quality packaging, no corrosion
protection and often manufactured by workers with minimal
skill, training or engineering knowledge. When considering
price, you must also consider quality and total cost. The
failure and resulting costs caused by using low quality
products, does not justify the slight price saving seen by
the purchaser alone. Here are a few examples of competing
products, and the many resulting problems that will prove
expensive to your business if you ignore quality and safety.
When dismounting a drive train or shaft, poor design and
material weakness become clearly visible in terms of the
time loss, and the replacement products needed. The use
of heavy tools, damaged bolts and components destroyed
during removal make re-installation impossible. As a result
the costs associated with increased operational delays,
extended docking time, re-engineering and replacement
products cannot be ignored.
... and poor design failure the result.
Low quality = danger and high costsAt SCHAAF we offer ‘A peace of mind Technology’, helping you make low quality examples like these part of history… and not your future.
Low-cost transportation boxes.
... with inconsistant tensioning force.Tensioner failure...
Dismounting of standard bolts with heavy tools... ...causing additional expense.
Poor quality shielding of hoses are a danger for life!
When pre-tensioning forces are not reached due to poor quality equipment, failures occur leading to danger and
damage. To understand high pressure just consider a 30kg mass resting on a 1mm2 area (The tip of a writing pen)
You are now considering 300N of force or 3000 bar. Unsafe high pressure equipment can kill!
1mm2
Certificates Approval given by all
classification societies
Material test reports
Specific test reports
Certificates in accordance with
special customer requirements
SCHAAF ReferencesA small selection of our ExpaTen and GripLoc supply references
Cruise vessel
“Mein Schiff 3”
Cruise Vessel
“CARNIVAL FREEDOM”
Cutter Suction Dredger
“TIAN JING HAO”
Car Carrier
“VIKING SEA”
Cruise vessel
“CARNIVAL LIBERTY”
Container vessel
“PONA”
Cruise Ferry
“COASTAL RENAISSANCE”
Various Air Craft Carrier
Container vessel
“FESCO BAYKAL”
Best in TechnologyOut of more than 3000 suppliers SCHAAF
received the award “Best in Technology”
from MAN Diesel & Turbo SE. In the last 30
years over 10000 orders for the companies of
MAN Diesel & Turbo SE were executed.
Quality AssuranceAll SCHAAF products are checked for material
quality, dimensional accuracy, correct functioning
and load-resistance. During order execution, they are
subject to continuous quality assurance measures
and are supplied together with detailed technical
documentation.
Certificates Approval given by all
classification societies
Material test reports
Specific test reports
Certificates in accordance with
special customer requirements
ServicesAll SCHAAF products are, of course, supplied packaged,
ready for installation and use. SCHAAF equipment is
user-friendly, reliable, and manufactured in accordance
with the highest level of technical know-how. Our
highly-motivated staff would be pleased to train your
personnel, in situ or at our works, in mounting and
dismantling the bolts.
Container vessel
“KING ALFRED”
Crude and Oil Product Carrier
“MV PETRODVORETS”
Bulker
“HEROIC”
Container vessel
“MAERSK BOSTON”
RoRo Cargo Ship
“Ulusoy 14”
LNG Tanker “Taitar N°1“
Cruise Vessel
“ROYAL PRINCESS”
Cruise Vessel
“QUEEN ELIZABETH”
Cargo vessel
“MASUREN”
Various Navy
Patrols
SCHAAF GmbH & Co. KGBruesseler Allee 22
41812 Erkelenz - Germany
Telephone: +49 - 24 31 - 9 77 70-0
Fax: +49 - 24 31- 9 77 70-77
E-Mail: [email protected]
Internet: www.schaaf-gmbh.com
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SCHAAF (Taicang) Co. Ltd. 萨尔福超高压液压技术(太仓)有限公司
No.8 North Loujiang Road, Taicang 215400, Jiangsu Province, P.R. China
中国江苏省太仓市娄江北路8号. 邮编:215400
Phone / 电话: +86 (0)512 -81 60 80 60
Fax / 传真: +86 (0)512 -81 60 80 61
E-Mail: [email protected]
Internet: www.schaaf.cn
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