compressors boosters nitrogen generators accessories … · compressors boosters nitrogen...

HIGH PRESSURE SOLUTIONSFrom the Air and Gas Experts

COMPRESSORS BOOSTERS NITROGEN GENERATORS ACCESSORIES

BAUER COMPRESSORS INC.

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

www.bauercomp.com

111.09.04.3SPsubject to alteration without notice or obligation

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CONTENTS COMPRESSORS

The fine art of high pressure

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COMPANY / 0104 Dedication to quality

COMPRESSION / 0206 Heart of the system08 Solutions for industry10 Nitrogen generation

PURIFICATION / 0312 Drying and purifying

STORAGE / 0414 Stored energy

DISTRIBUTION / 0516 The fine art

APPLICATIONS / 0618 Systematic success

NITROGEN GENERATORS ACCESSORIESBOOSTERS

Contents

BAUER is especially capable of workingwith clients on a worldwide basisbecause of our vast network of salesand service centers around the globe.BAUER’S U.S. operations includebranch offices in Michigan, Californiaand Florida. We specialize in all highpressure market segments includingbreathing air, plastics technology,industry, helium recovery, natural gasand nitrogen generation in addition tomany other common and uniqueapplications.

EXPERIENCE FOR YOUR BENEFITBAUER compressors are field-proven ina multitude of diverse high pressureapplications worldwide. More than 60years of experience and research anddevelopment are available to you tohelp solve your high pressure air or gasrequirement no matter if it is a com-mon or unique application. We areworld renowned for reliability anddurability, and BAUER as a company isrecognized as the world’s foremostinnovative designer and manufacturerof high pressure compressors of thevery highest quality.

BAUER GROUP

SINGAPORE

Dedication to qualityDedication to quality

CHILE

INDIA

EGYPT

UNITED ARAB EMIRATES

CHINA

UNITED KINGDOM

ITALY

JAPAN

FRANCE

AUSTRIA

USA

GERMANY

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I280-100 E3

COMPRESSORS

BAUER Block Manufacturing Geretsried, Germany

COMPANY

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DEDICATION TO YOUBAUER is committed to the philosophythat customer satisfaction is achievedthrough a strategy of continuousimprovement using in-house researchand development, engineering, manu-facturing and support services. OurISO 9001 registered quality manage-ment system is testament to our com-mitment to quality and customer satis-faction.

CUSTOMER SATISFACTIONBegins with expert system evaluationand continues with the design, instal-lation, training and support servicesto ensure the highest quality andoptimum performance of the product.


BAUER COMPRESSORS INC. Norfolk, Virginia USA (Headquarters for USA and Latin America)

MANUFACTURING | ENGINEERING | SALES | MARKETING | SERVICE | TRAINING | SPARE PARTS | WAREHOUSE

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Heart of the systemHeart of the system

COMPRESSION COMPRESSORS

COMPRESSORS AND BOOSTERS

100 and 120.x Booster 12.x 15.x and 18.x Booster 15.x

BAUER ADVANTAGES...Wide range of capacity and pressure inboth compressor and booster configu-ration allows tailoring a solution tomeet specific requirements.

Proven air-cooled design is economi-cal, reliable and environmentallyfriendly. An external power source isnot required and no coolant.

Large surface area and fine ribbing oncylinders provides efficient heat dissi-pation for lower operating tempera-tures.

Aftercooler provides low dischargetemperature. Supplemental cooling atthe outlet is not required.

Pressurized lubrication ensures reliablelubrication of all internal componentsfor extended compressor life. Oil filterprotects the lubrication system.

Roller or needle bearing used at eachbearing surface for reduced frictionand optimum mechanical efficiency.Compressor runs cooler, oil life isextended and maintenance is reduced.

Heavy-duty roller bearings to supportthe crankshaft. 30,000 hours designlife.

Aluminum alloy crankcase usedthrough 30 hp enables compactdimensions because of rapid heat dis-sipation. Cast iron crankcase used on40 hp and greater to support greaterforces. High capacity cooling fan(s)provide efficient cooling.

Encapsulated crankcase to protect theenvironment from oil laden mist.

High efficiency intake filter to protectthe compressor from damaging parti-cles.

Safety valve after each stage of com-pression to protect the compressorfrom overpressure and to safeguardthe operator. Gas compressors andboosters also include a safety valve atthe inlet.

Balanced flywheel and counterbal-anced crankshaft results in nearlyvibration-free operation. BAUER com-

pressors and boosters do not requirespecial foundations which reducesinstallation cost.

Readily accessible valves do not requiredisassembly of compressor piping foreasy accessibility and reduced mainte-nance cost and downtime.

Corrosion resistant materials used forcoolers, separators and valves forlonger life and reduced maintenance.

Genuine spare parts at affordableprices.

Operation and maintenance manualwith illustrated parts lists.

...FOR YOUR BENEFIT

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22.x 23.x 25.x and 28.x


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NATURAL GAS

Solutions for industrySolutions for industry

HORIZONTAL

NITROGEN GENERATORS

VERTICAL CUSTOM PACKAGING

OFFSHORE


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Our Product Range

1000

psig

(69

bar)

5000

psi

g (3

45 b

ar)

6000

psi

g (4

14 b

ar)

5 Stages*4 Stages3 Stages2 Stages1 Stage

3)2)

1) 900 psig (62 bar) 2) 725 psig (50 bar) 3) 5000 psig (345 bar) *Available for 7000 psig (483 bar) A = Air / Nitrogen G = Helium / Argon C = Natural Gas

Model Motor Available Series Capacity15 scfm 30 45 60 75 90 105 120 135 150 165

hp kw A G C 425 l/min 850 1275 1700 2120 2550 2970 3400 3820 4245 4670

Compressors

12.4 5 3.5 •

22.5 15-20 11-15 •

23.4 30-40 22-30 •

25.4 50 37 •

28.2 60-75 45-55 •

25.51) 100 75 •

28.31) 125-150 90-110 •

100 5 3.5 • • •

120 7.5 5.5 • • •

15.1 7.5-15 5.5-11 • • •

150 15 11 •

180 20 15 •

15.2 20 15 •

220 25-30 18-22 • • •

23.1 40 30 • •

230 40 30 •

250 50-60 37-45 • •

280 75-100 55-75 • •

100H 5 3.5 •

12.14 7.5-10 5.5-7.5 •

15.11 15 11 •

22.42 25-30 18-22 •

18.1 20 15 • •

25.9 60 45 • •

25.18 75 55 •

Boosters

12.3 5-10 3.5-7.5 •

12.2 5-7.5 3.5-5.5 •

15.3 10-15 7.5-11 •

15.4 15 11 •


CheckValve

Motor

Feed AirCompressor

Aftercooler Check

(auto drains)

Motor

OxygenOxygen MonitorMetering Valve

Processing PressureN2

Membrane Air Separator

O2, CO2,H2O Vent

High PressureCompressor

Purif icationPressure Gauge

HeatExchanger

MixingValve

Permeate

Sensor

InletDome LoadRegulator

FinalSeparator

InletProportional

Valve

Valve

MaintainingValve

Air

Filters

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BAUER NITROGEN GENERATION PROCESS

Nitrogen generationNitrogen generation


WHY BUY NITROGEN WHENYOU CAN MAKE YOUR OWN?The BAUER SNG Series II NitrogenGenerator is a self-contained, fullyintegrated, modular system that elimi-nates the hazards involved with thehandling of high pressure cylinders aswell as the burden of merchant sup-plied nitrogen gas.

The BAUER SNG Series II NitrogenGenerator is a complete systemdesigned for the on-demand supply ofnitrogen gas at purities up to 99.5%.

SEPARATION MODULEThe BAUER SNG Series II NitrogenGenerator generates nitrogen gasthrough membrane separation whichallows for the rapid production of lowcost, high purity nitrogen gas ondemand at the point of use. Ambientair is compressed and supplied to theseparator where water vapor, variousgases such as O2, CO2, and hydrocar-bons are released to atmosphere leav-ing high purity nitrogen gas.

STANDARD FEATURES– High durability membrane air

separators

– Purity up to 99.5% Nitrogen

– Feed air compressor, if required

– High pressure booster, if required

– Electric motor drive

– UL® master control panel withinteractive touch screen interfacefor operation, maintenance andtroubleshooting.

– Single-point power supplyconnection

– On-line percent oxygen monitor

– Pressure sensors for oil and finalproduct pressure

– Emergency stop push button

– Visible alarm annunciation

– Sound attenuated enclosures forcompressors and membranemodule

AVAILABLE ACCESSORIES– CE-complaint electrical assembly

– Second language for controls /documentation

– Distribution panel

– Storage

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SNGII-LP

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THE RIGHT FILTER SYSTEM FOR THE RIGHT APPLICATIONProcessing of the compressed medium is essential for trouble-free operation of a high pressure system, and the selection of thecorrect method of processing is essential to meet the gas quality requirements for the application. BAUER is an internationalleader in the design and manufacture of high pressure processing systems ranging from moisture separators to regenerativedryers and their accessories. And since BAUER is the manufacturer of the compressor and processing system, you have theassurance that these two important components are perfectly matched to meet specific requirements.

Drying and purifyingDrying and purifying

PURIFICATION COMPRESSORS

SEPARATORCondensed oil and water

AIR KOOLRefrigerated dryer

P-FILTER SYSTEMNon-regenerative dryer | purifier

SECCANTRegenerative dryer | purifier

OUR PROCESSING SOLUTIONS

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FINAL SEPARATORAll BAUER high pressure compressors /boosters include a final separator. Thefinal separator removes the condensedoil and water droplets from the com-pressed medium following its exit fromthe aftercooler.

AIR-KOOLAIR KOOL is a refrigerated, counter-flow heat exchanger that increases theamount of condensed oil and waterdroplets in the compressed mediumfor removal by the final separator. AIRKOOL increases the efficiency of thefinal separator and reduces operatingcosts by extending the life of the avail-able filter cartridges. AIR KOOL is avail-able for BAUER high pressure compres-sors / boosters up to 22 scfm withoperating pressures between 1800and 7000 psig.

P-FILTERA P-FILTER system, if required, can beinstalled downstream of the final sep-arator and available AIR KOOL. P-FIL-TER systems can be tailored to removespecific or a variety of contaminants,and can achieve an atmospheric dewpoint of -94 ºF. These systems work bythe process of adsorption which issafe, effective, efficient and economi-cal. P-FILTER systems use replaceablecartridge(s) that makes operation andmaintenance clean, safe and simple.P-FILTER systems have no movingparts, do not require power or lose anyof the compressed medium for purg-ing. The only required maintenance isto replace the cartridge(s) after theirservice life has expired. P-FILTERSystems are available for BAUER highpressure compressors and boosters upto 40 scfm with operating pressuresfrom 1300 to 7000 psig.

SECCANTSECCANT is the ideal, cost-effectiveregenerative dryer for heavy duty orcontinuous duty applications. Theseheatless, regenerative dryers requireonly a small portion – maximum 5% –of the compressed medium for theregeneration process. SECCANT dryersuse replaceable cartridges that makesoperation and maintenance clean, safeand simple. SECCANT dryers canachieve an atmospheric dew point of -94 ºF. SECCANT is available for allBAUER high pressure compressors upto 125 scfm with operating pressuresfrom 1300 to 6000 psig. A P-FILTERpurifier can be added downstream foradditional purification requirements.

SECURUSSECURUS is a low-cost accessory forthe P-FILTER systems and SECCANTdryers that uses patented technologyto reduce the operating cost of thedrying system by ensuring 100% uti-lization of the dryer cartridge(s). SECU-RUS is unique in that the sensingdevice is embedded in the cartridge,thus ensuring a highly accurate meas-urement of the cartridge’s life.

ADVANTAGESAll BAUER cartridges process the com-pressed medium to comply with thequality requirements for industrial airand gases according DIN ISO 8573-1Class 2 for oil content and Class 3 formoisture content.

All separator and filter chambers aremade of a high-strength, fatigue andcorrosion-resistant material. Allmachining is done in-house to assurethe closest tolerances and highestquality. The final product is stampedwith material lot and production num-bering for traceability. The entireprocess and the final product is super-vised and approved by TÜV, an inter-nationally recognized independentinspection agency.

STORAGE COMPRESSORS

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Stored energyStored energy

The volume of storage required for aspecific application depends upon:

A. Consumption rate of the system

B. Capacity of the compressor/booster

C. Deadband of the final pressure switch

BAUER is knowledgeable in the appli-cation of storage to medium and highpressure applications. We offer storagesystems that meet the code require-ments of the American Society ofMechanical Engineers (ASME) and theDepartment of Transportation (DOT).Additional information can be found inour brochure for Storage Systems andAccessories.

STANDARDENERGY IN RESERVEStorage is a reservoir from which acompressed medium can be used tomeet the demands of an applicationwhile protecting the compressor fromthe direct demand of the applicationand preventing short-cycling of thecompressor and motor. In its simplestform storage and a pressure regulatorcan be used to provide the compressedmedium at a constant pressure, butstorage can also satisfy unpredictabledemands of the application which thecompressor can not meet. Storage canbe in the form of a single bank (buffer)or arranged in multiple banks. Thecompressor and storage must be sizedand configured as an engineered sys-tem for optimum efficiency and costsavings. BAUER recommends that thecompressor does not start more than 4times per hour.


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Gauge Air Nitrogen Argon Heliumpressure

psig bar scf m3 scf m3 scf m3 scf m3

1000 69 70.29 1.99 69.30 1.96 71.79 2.03 66.37 1.88

1500 103.4 104.77 2.97 102.74 2.91 108.50 3.07 98.12 2.78

2000 137.9 137.77 3.9 134.90 3.82 145.30 4.11 128.55 3.64

2500 172.4 169.11 4.79 165.39 4.68 181.50 5.14 158.08 4.48

3000 206.9 198.96 5.63 193.82 5.49 216.30 6.13 186.78 5.29

3500 241.4 226.14 6.4 220.26 6.24 249.20 7.06 214.66 6.08

4000 275.9 251.34 7.12 244.39 6.92 279.90 7.93 241.79 6.85

4500 310.3 274.85 7.78 266.60 7.55 308.30 8.73 268.19 7.6

5000 344.8 296.57 8.4 286.67 8.12 334.40 9.47 293.90 8.32

5500 379.3 316.03 8.95 305.80 8.66 358.40 10.15 318.95 9.03

6000 413.8 334.06 9.46 322.77 9.14 380.30 10.77 343.37 9.72

TECHNICAL DATA FOR GASES AT PRESSUREThe table below lists the volume of different gases that can be compressed into one (1) cubic foot water volume at the givenpressure. The information is based on 70 ºF and accounts for the compressibility of the gas. The table can be used to calculatethe volume of air or gas that can be stored in a cylinder of known water volume. Likewise, the water volume of a cylinder canbe calculated if the capacity of air or gas stored in the cylinder is known.

CUSTOM DESIGNSCOMPRESSOR WITH STORAGE

The fine artThe fine art

SAFETY AND RELIABILITYHigh pressure gas is used in a multitudeof industrial applications. The design ofa safe, efficient distribution system for ahigh pressure gas is critical to the suc-cessful use of that gas for a particularapplication. BAUER has over 60 yearsexperience in the design and manufac-ture of distribution systems for highpressure. We have a reputation for pro-viding safe, reliable, user-friendly distri-bution systems ranging from simplepanels to complex systems controlledby a PLC and with touch-screen opera-tor interface. Standard and customdesigned systems are available.

BAUER uses only quality componentsthat are specifically designed for highpressure. All components are appliedwithin their design parameters andinclude a safety factor of up to 4 to 1.

For permanent installations, BAUER rec-ommends the use of seamless stainlesssteel tubing. All tube runs are support-ed to prevent the transmission of vibra-tion through the tubing and to the restof the system. High pressure hose isused for non-permanent installations orwhere flexibility is required.

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DISTRIBUTION COMPRESSORS

All panel mounted pressure regulatorsare supplied with pressure gauges forinlet and outlet pressures and a safetyvalve for overpressure protection ofdownstream components.

Each high pressure distribution systemis carefully designed to include pressureindicating devices and safety, isolation,vent and drain valves as required. Allpanel mounted devices are clearly iden-tified with labeling. More complex sys-tems include a schematic diagram aspart of the labeling for operator refer-ence.

BAUER manufactures industry-leadingdistribution systems for several marketsincluding SCBA cylinder refilling andgas-assist injection molding.

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Systematic successSystematic success

ELECTRONICS– Nitrogen Blanketing

EXPLORATION– Seismographic - land and offshore

– Well revitalization - oil, gas andwater

FIRE FIGHTING– Aircraft dispersed foam

– Water mist fire suppression

HYDRAULICS– Air-oil accumulator

HYDROPOWER PLANTS– Governor control

– Wicket gate control

NITROGEN GENERATION– Blanketing

– Testing

– Purging

– Parts cleaning

OIL AND GAS– Pipeline pressure testing

– Rig stabilization

AUTOMOTIVE INDUSTRY– Test sleds

– Wind tunnel

– Testing

– Natural gas vehicle refueling

AVIATION– Engine starting

– Aircraft maintenance

– Testing

CHEMICAL INDUSTRY– Compressors with explosion proof

controls for various applications

– Emergency shutdown

COMPONENT TESTINGAND CALIBRATION– Pressure gauges

– Relief valves

– Valves and valve actuator

– Tubing and hose

– Pipe and transducers

CYLINDER REFILLING– Storage

– Air rifle

– Less lethal weapons and paintball

ELECTRIC POWER PLANTS– Turbine starting

– Circuit breaking

APPLICATIONS COMPRESSORS


IVE180-DUPLEX

PAINTBALLLAW ENFORCEMENT– High pressure air supply for fields,

stores and tournaments

– Less lethal weapons

– Training simulators

RESEARCH– Industry

– Educational

– Aviation

SHIPBOARD– Cable compensation

– Air guns for seismographicexploration

– Engine starting

SPECIAL TECHNOLOGIES– Propriety designs for commercial

and military use

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