cng brochure

HIGH PRESSURE COMPRESSORSFor Natural Gas Vehicle Refueling

SYSTEMS SERVICE TRAINING WORLDWIDE

BAUER COMPRESSORS INC.

1328 Azalea Garden RoadNorfolk, VA 23502TEL. +1 (757) 855-6006FAX +1 (757) [email protected]

www.bauercomp.com

152.12.04.1SPsubject to alteration without notice or obligation

2

CONTENTS SYSTEMS

From the Manufacturer - Packager

MISSION STATEMENTTo be the global leader by supply-ing the best quality product whilecontinuously improving throughinnovation.

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INTRODUCTION / 0104 Heart of the system06 BAUER CNG Systems

COMPRESSION / 02

08 Compressor solutions for natural gas

PRODUCTS / 0310 Compact series12 Medium duty series14 Heavy duty series

ACCESSORIES / 0416 System enhancements

COMPANY / 0518 Lifecycle performance

BAUER GROUP / 0620 Worldwide

EXPERTS / 0722 Planning

TRAINING WORLDWIDESERVICE

Contents

Heart of the system

INTRODUCTION SYSTEMS

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NEW BAUER C52 HIGH CAPACITYWATERCOOLED COMPRESSOR

HISTORY - trusted industryleader for over 60 yearsFor the past 60 years, BAUER compres-sors have stood the test of time for thehighest level of performance, quality,safety and innovation. All BAUER com-pressors are designed and manufac-tured in-house with complete controlof every step to ensure that BAUER’suncompromising standards for ulti-mate performance, unmatched relia-bility, highest durability and lowestcost of ownership are met. BAUER iswell known for their high tech preci-sion manufacturing and qualityprocess, resulting in products whichoutperform and outlast any othercompressor brand on the markettoday.

INNOVATION - ultimate per-formance and reliabilityAt BAUER, we are committed to pro-vide our customers with the mosttechnologically advanced products inthe world. Only the latest CAD andfinite element calculation programs areused in the design of each product. Tomaintain our technological edge,BAUER re-invests a large portion ofcorporate earnings back into R&D.Simultaneously we draw on our morethan a century of machine buildingheritage to advance our causes for thefuture. The result: Products which arebuilt to attain the highest standards ofperformance and reliability.

Heart of the system


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BAUER COMPRESSORS INC.Norfolk, Virginia is registered to ISO 9001:2000

The New BAUER High Inlet PressureCompressors: Computer optimizedbionic-shaped crankcase allowsconsistent absorption of internalgas forces in the compressorsystems under pressure.

QUALITY - lowest cost of own-ershipAt BAUER, our world renowned qualityis a result of being vertically integrated.We maintain control of the entire pro-duction process, starting from R&D, toengineering & design, to manufactur-ing & assembly. Only the highestgrade materials and state of the artprecision manufacturing methods areused in the making of each compres-sor. To ensure consistent qualitythroughout, our entire manufacturingprocess from the compressor to com-plete system is ISO9001 certified.Every unit is put through rigorous test-ing by our QC department beforerelease from our factory for shipping.The result: A highly reliable productwhich keeps on performing with mini-mal cost of ownership.

The new line of BAUER com-pressors are rated for 30,000hours of continuous operationwith lifecycle support of up to40 years.

INTRODUCTION SYSTEMS

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Since the beginning of the 1970’s,BAUER has been manufacturing sys-tems solutions for filling vehicles run-ning on Compressed Natural Gas(CNG). There are currently over 1,400BAUER CNG compressor systems inoperation worldwide. Each BAUERCNG system is built with the same levelof innovation and quality as the BAUERcompressor at the heart of the system.

RANGE AND FLEXIBILITY - FromCompression to Turnkey CNGFueling System for Any SizeFleetAt BAUER we offer our customers withcomplete flexibility. Our product offer-ing ranges from simple compressionsystems all the way to completeturnkey systems with storage, priority,sequencing, drying, purification as wellas dispensing. Our customers have theoption to choose from a number ofpre-engineered systems designed formaximum value and shorter lead timeswith a wide performance range toaccommodate any size fleet. For spe-cial customer needs, we also offer cus-tomized CNG solutions.

BAUER CNG SystemsInlet Drying

Compression System

Storage and Priority - Sequential System

Dispensing


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SAFETY - Built Into Every SystemWith over 40 years of CNG experience,safety is an integral part of the designof all BAUER CNG systems. All compo-nents are built to the latest edition ofthe NFPA 52 code and all critical con-trol points such as temperatures, pres-sures and electrical loads are continu-ously monitored throughout theprocess to ensure safe and reliableoperation of the compression system.

TWO YEAR WARRANTY - On AllBAUER CNG SystemsWe are so confident of our quality, thatall BAUER CNG systems are warrantiedfor two years for both parts and labor.In addition, we guarantee that all com-

pressors are supported with spare partsfor 40 years. This level of support isunmatched in the industry.

24/7 CUSTOMER SUPPORTAll BAUER CNG systems are supportedby a nationwide network of BAUERfactory trained technicians. We areavailable 24/7 for technical and spareparts support. We also offer remotemonitoring of your BAUER CNG systemfor early problem detection and ensur-ing the highest level of uptime and reli-ability for years to come.

COMPRESSION SYSTEMS

Compressor Solutions for Natural Gas

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Compressor Solutions for Natural Gas

Compact SeriesAir CooledCompressor

V-Belt Drive

up to 9 cfmC120

Compact SeriesAir CooledCompressor

V-Belt Drive

up to 22 cfmC15

MediumCapacity AirCooledCompressor

V-Belt Drive

up to 40 cfmC22

Workhorse AirCooledCompressorCapacity

V-Belt Drive

up to 50 cfmC23.1

Versatile State-ofthe-Art Air orWater CooledCompressor /Suitable for HighInlet Pressure

V-Belt Drive

65 to 145 cfmC23

Latest State-of the-Art High CapacityWater Cooled CompressorSuitable for High Inlet Pressure

Direct Drive

up to 700 cfmC52

up to 150 cfmC28

Latest State-of the-Art High CapacityWater CooledCompressor /Suitable for HighInlet Pressure

Direct or V-belt Drive

up to 350 cfmC26

Workhorse AirCooledCompressorCapacity

V-Belt Drive


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Compact seriesCompact series

PRODUCTS SYSTEMS

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Control Panel

ExplosionproofenclosureNEMA 7

Inlet Buffer

Vapor Recovery

C15.1 Compressor

Optional Weatherproof Enclosure

BAUER Compact Series Self Contained Compression System

Available in Simplex or Duplex configuration.


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BAUER air-cooled, pressure lubricated, continuous-dutyrated, multi-stage reciprocating compressor/boosterInlet buffer tankEncapsulated crankcaseCrankcase heaterGas-tight relief valve for each stageAutomatic condensate drain systemVapor recovery systemLow oil pressure alarmHigh temperature alarmLow/high inlet pressure alarmTEFC electric motorLocally mounted control panelEmergency stop pushbutton

Stainless steel tubing, tube fittings and high pressureinstrument pipe fittings Skid mountedBuilt to Class 1, Division 2, Group D and NFPA 52,latest editions24 month warranty

STANDARD SCOPE OF SUPPLY

Daily capacity in equivalent gallons based on daily compressor operating hours

AVAILABLE ACCESSORIESExplosion-proof motorHigh pressure dryerCabinetStoragePriority and/or sequential valve panelFill post(s) and/or dispenser(s)Card reader

Technical Data

Model Capacity Inlet pressure Number Speed Motor power Power requirement of stages max at max final

CFM DGE/H GGE/H psi (g) rpm hp hp

5 psi inlet

C120 9 4.1 4.5 - 3 1350 7.5 7.0

C15.1 18 8.2 9.0 - 4 1350 15 14.2

C15.2 22 10.2 11.2 - 4 1350 20 17.8

15 to 60 psi inlet

C15.4-10 16 7.3 8.0 30 3 1350 10 9.9

C15.4-15 27 12.3 13.5 60 3 1350 15 14.6

Model 4 hours 6 hours 8 hours 10 hours 12 hours 14 hours 16 hours 18 hours

DGE GGE DGE GGE DGE GGE DGE GGE DGE GGE DGE GGE DGE GGE DGE GGE

C120 16 18 25 27 33 36 41 45 49 54 57 63 65 72 74 81

C15.1 33 36 49 54 65 72 82 90 98 108 115 126 131 144 147 162

C15.2 41 45 61 67 82 90 102 112 122 135 143 157 163 179 184 202

C15.4-10 29 32 44 48 58 64 73 80 87 96 102 112 116 128 131 144

C15.4-15 49 54 74 81 98 108 123 135 147 162 172 189 196 216 221 243

Maximum operating pressure = 5000 psi | Tolerance on performance values, +/- 5% | Information subject to modification without notice or obligation.

Medium duty series

Vapor RecoverySystem

Inlet Buffer

Medium duty series

PRODUCTS SYSTEMS

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C22 Compressor

Dryer

BAUER Medium Duty Self Contained Compression System


Available in Simplex or Duplex configuration.


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Technical Data



5 psi inlet

C22.0 40 18.2 20.0 - 4 1300 30 29.2

C23.1 50 22.7 25.0 - 4 1400 40 38.4

C23.0 65 29.5 32.5 - 4 1400 50 49.6

C25.0 75 34.1 37.5 - 4 1050 60 57.6

15 to 550 psi inlet

C23.2 75 27.3 30.0 15 4 1400 50 30.4

C23.10 80 36.4 40.0 65 4 1200 50 44.0

C23.12 100 45.5 50.0 145 4 1200 50 46.5

C23.13 115 52.3 57.5 230 4 1200 50 45.7

C23.14 145 65.9 72.5 550 4 1200 50 43.1




C22.0 73 80 109 120 145 160 182 200 218 240 255 280 291 320 327 360

C23.1 91 100 136 150 182 200 227 250 273 300 318 350 364 400 409 450

C23.0 118 130 177 195 236 260 295 325 355 390 414 455 473 520 532 585

C25.0 136 150 205 225 273 300 341 375 409 450 477 525 545 600 614 675

C23.2 109 120 164 180 218 240 273 300 327 360 382 420 436 480 491 540

C23.10 145 160 218 240 291 320 364 400 436 480 509 560 582 640 655 720

C23.12 182 200 273 300 364 400 455 500 545 600 636 700 727 800 818 900

C23.13 209 230 314 345 418 460 523 575 627 690 732 805 836 920 941 1035

C23.14 264 290 395 435 527 580 659 725 791 870 923 1015 1055 1160 1186 1305


Large duty seriesLarge duty series

PRODUCTS SYSTEMS

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C28 Compressor

BAUER Heavy Duty Self Contained Compression System



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Technical Data




C28.0 273 300 409 450 545 600 682 750 818 900 955 1050 1091 1200 1227 1350

C52.0 545 600 818 900 1091 1200 1364 1500 1636 1800 1909 2100 2182 2400 2455 2700

C26.2 309 340 464 510 618 680 773 850 927 1020 1082 1190 1236 1360 1391 1530

C26.10 500 550 750 825 1000 1100 1250 1375 1500 1650 1750 1925 2000 2200 2250 2475

C26.12 564 620 845 930 1127 1240 1409 1550 1691 1860 1973 2170 2255 2480 2536 2790

C26.13 636 700 955 1050 1273 1400 1591 1750 1909 2100 2227 2450 2545 2800 2864 3150

C26.14 645 710 968 1065 1291 1420 1614 1775 1936 2130 2259 2485 2582 2840 2905 3195

C52.10 1000 1100 1500 1650 2000 2200 2500 2750 3000 3300 3500 3850 4000 4400 4500 4950

C52.12 1127 1240 1691 1860 2255 2480 2818 3100 3382 3720 3945 4340 4509 4960 5073 5580

C52.13 1273 1400 1909 2100 2545 2800 3182 3500 3818 4200 4455 4900 5091 5600 5727 6300

C52.14 1291 1420 1936 2130 2582 2840 3227 3550 3873 4260 4518 4970 5164 5680 5809 6390




5 psi inlet

C28.0 150 68.2 75.0 - 4 1120 125 120.6

C52.0 300 136.4 150.0 - 4 1500 250 241.2

15 to 550 psi inlet

C26.2 170 77.3 85.0 15 4 1500 125 118.9

C26.10 275 125.0 137.5 65 4 1500 150 149.0

C26.12 310 140.9 155.0 145 4 1500 150 141.6

C26.13 350 159.1 175.0 245 4 1500 150 138.6

C26.14 355 161.4 177.5 550 4 1500 125 103.5

C52.10 550 250.0 275.0 65 4 1500 300 298.0

C52.12 620 281.8 310.0 145 4 1500 300 279.8

C52.13 700 318.2 350.0 245 4 1500 300 277.1

C52.14 710 322.7 355.0 550 4 1500 250 207.0

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System enhancementsSystem enhancements

ACCESSORIES SYSTEMS

DRYINGTo ensure pure gas, free of moisture,BAUER offers complete solutions fornatural gas drying. A typical configura-tion consists of a low pressure gas inletdrying system which strips the incom-ing gas of moisture before compres-sion. BAUER also offers high pressuredryers which perform the same func-tion after compression.

LOW PRESSURE DRYER

BAUER HIGH PRESSUREDRYER SYSTEM

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STORAGE FOR FAST FILLBAUER offers a variety of storage con-figurations depending on your fillrequirements. A typical fast fill systemconsists of an array of ASME high pres-sure vessels (tube or cylindrical)arranged in a low, mid and high bankconfiguration. The charging and dis-charging of the banks is controlledthrough the priority and sequencingcontrols.

PRIORITY AND SEQUENCINGCONTROLSBAUER Priority Controls determine thefilling sequence of each storage bankby the compressor based on the actualreal-time pressure (gas fill level) in eachbank. The Priority Control algorithm isembedded in the PLC of the compres-sion system.

Sequencing Controls determine thedischarging sequence of the system’slow, mid and high storage banks basedon the real-time demand from thevehicles. The Sequencing Controlsoptimize vehicle fill time based on theactual pressure (fill level) of the vehiclestorage vessels and available pressure(fill level) in each storage bank. TheSequencing algorithm is typicallyembedded in the gas dispensing sys-tem.

DISPENSERS AND FILL POSTSBAUER offers a complete line of lead-ing brand CNG filling systems. Fromsimple filling posts for private fleets, tosophisticated dispensers with creditcard access for public access stations,we can accommodate any customerneed.

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QUALITYAll BAUER compressors are built inGermany at Bauer’s state-of-the-artfacility near Munich. The facility is atribute to high quality German manu-facturing using both highly experi-enced skilled machinists as well as thelatest automated CNC machiningequipment. Every compressor mustpass a rigorous performance testunder real life conditions before it is

allowed for shipping.

For the past 35 years, the BAUERNorfolk Virginia facility has been dedi-cated to building the highest qualityCompression Systems for various appli-cations from Breathing Air Systems toa wide variety of Industrial Systems toCNG Systems for compressing and fill-ing natural gas for vehicle fueling. Likeits German counterpart, the BAUER

Lifecycle performanceLifecycle performance

SYSTEMS

BAUER COMPRESSORS INC. Norfolk, Virginia USA (Headquarters for USA and Latin America) and BAUER Block Manufacturing Geretsried, Germany

COMPANY

CUSTOMER SATISFACTION -through lifecycle performanceBAUER is committed to the philosophythat customer satisfaction is achievedthrough providing high performance,quality products which do not degradeover time and which are backed bystrong support for the life of theequipment with the lowest cost ofownership. We call this LIFECYCLEPERFORMANCE.

CAD DESIGN LASER CUTTING ROBOTIC BRAKE

VERTICALLY INTEGRATED MANU

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Latest machining & manufacturing methods

Norfolk facility utilizes the latest insophisticated manufacturing methods.To ensure precision, repeatability, scaleand quality the manufacturing processis highly automated utilizing and arrayof laser cutters, robotic brakes , robot-ic welders and CNC high pressure tubebenders. Assembly is performedthrough highly experienced and skilledworkers. And, in accordance withBAUER’s high quality standards, all sys-tems are performance tested underreal-life conditions before shipping tothe customer.

Both BAUER’s Compressor Factory inGermany and BAUER’s Systems Factoryin Norfolk, VA are ISO9001 certified.

SUPPORTAt BAUER we view World-ClassCustomer Support as an essential partof our business. From 24-hour serviceavailability to extremely long productsupport life cycles (up to 40 years) westand behind our customers for as longas they own their equipment.

- We stock all critical spare parts whichare required for the operation of thecompression system for immediateshipment to our customers fromNorfolk, VA.

ROBOTIC WELDING BAUER UNIVERSITY TRAININGQUALITY

Remote monitoring

- We offer live Help Desk Support fromNorfolk, VA to assist our customerswith technical questions and helpthem diagnose problems quickly overthe phone.

- We offer a team of highly skilled fac-tory-trained technicians for onsiteinstallations and technical support atour customers’ facility.

- We offer remote diagnostics to forearly detection of problems andremote diagnosis as well as trou-bleshooting.

- We offer a variety of factory, onsiteand remote, computer-based trainingcourses to keep our customers compe-tent in operating, maintaining andtroubleshooting their equipment.

- We offer our customers an onlineportal into our customer intranetwhich is designed to provide access totechnical information, expert databas-es, machine manuals as well as sharingand exchanging information regardingtheir BAUER compression system.

In summary, at BAUER we are commit-ted to provide our customers with aworld-class customer service experi-ence. We will do whatever it takes tomake sure that our customers getwhat they need whenever they needit.

UFACTURING IN THE USA

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Worldwide

BAUER GROUP SYSTEMS

BAUER OFFICESNORFOLK, VA (USA Main Office)

DALLAS, TX

MIAMI, FL

DETROIT, MI

SAN FRANCISCO, CA

LOS ANGELES, CA

COLOMBIA

CHILE

BRAZIL

GERMANY

AUSTRIA

FRANCE

ITALY

UNITED KINGDOM

JAPAN

SINGAPORE

CHINA

EGYPT

INDIA

AUSTRALIA

RUSSIA

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1328 Azalea Garden Rd. | Norfolk, VA 23502TEL. +1 (757) 855-6006FAX +1 (757) [email protected]

www.bauercomp.com

InformationCustomer: Attention:

Street: City / State / Country:

Phone: Mobile:

Fax: e-mail:

Date needed by: Potential order date:

Application:

Gas quality1 What is the pipeline pressure of the gas at the site (psig)?

2 Is the gas pipeline quality and does it meet the requirements of NFPA 52?

3 What is the moisture content of the gas (lbs / MMscf)?

Power1 What is the preferred prime mover, electric motor or natural gas engine?

2 Specify the electrical classification for the site (e.g. Class 1, Group D, Division 1 or Division 2).

3 Specify the electrical service(s) available at the site (volts/phase/hertz). Note, for natural gas engine drive 120/1/60 is required.

EXPERTS SYSTEMS

Planning

QUESTIONNAIREPlease complete as much of the information as possible so that we can size the compressor and/or storage system along withthe appropriate ancillary equipment.

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Fleet information1 How many NGVs are to be refueled? What is the fill pressure(s) (psig)?

2 How many are to be slow filled? How many are to be fast filled?

3 What is the NGVs stored gas volume or water volume or GGE (scf or scf w.v. or GGE)? Note, 125 scf is equivalent to one gallon of gasoline; 140 scf is equivalent to one gallon of diesel.

4 Describe the fleet, e.g. cars / pickups / vans / forklifts / buses, etc.

5 What is the average daily fuel usage for each NGV or the average daily mileage for each NGV or the average daily run time for each NGV (e.g. forklift)?

6 What is the typical fuel efficiency for the NGVs (mpg or gallons per hour for forklifts)?

7 Will the station be for public or private access?

8 How many days per week is the fleet in service? How many hours per day is the fleet in service?

9 Specify the peak demand period(s) and how many NGVs refuel during each peak demand period.

Station requirements1 Is there a requirement for a redundant compressor? yes no If yes, is 50% or 100% redundancy preferred?

2 What is the ambient temperature range at the site (°F min - °F max)?

3 Is an enclosure required? yes no Noise level requirement (dBA)?

4 How many fast fill hose drops are required?

5 Is mass flow metering required for fast fill?

6 What type of dispenser is required for fast fill, fill post or electronic (metered) dispenser?

7 How many slow fill hose drops are required?

8 Is mass flow metering required for slow fill?

9 Is fuel management required? Do you have a fuel management system existing?

10 Please provide any other information about the fleet or site that may assist us in our evaluation.

In addition to answering these questions, we urge the purchaser and/oruser to become familiar with the latest addition of NFPA 52 and to con-tact the local gas utility and the local authority having jurisdiction (AHJ)before writing a specification or purchasing equipment. Contact BAUERfor assistance.

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1328 Azalea Garden Rd. | Norfolk, VA 23502TEL. +1 (757) 855-6006FAX +1 (757) [email protected]

www.bauercomp.com

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