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Bauer CNG |
CNG
Pro natural gas
- full speed ahead for the environment,
mobility and cost-effectiveness
Top reliability and quality
standards have made Bauer a leader
in all fields of its product range
on the international market. This level
is maintained by highly qualified personnel
backed by many years of experience
in all company areas and is subject
to on-going improvement. And last but
not least, this standard was also achieved
through the introduction of a quality
assurance system in accordance with
the high requirements of ISO 9001.
Already in 1997 the company was certified
by TÜV Product Service Munich.
CNG Filling Stations - That Meet Your
Specific Requirements
 Planning & Decision Criteria
Filling mode:
slow fill or fast fill
Slow Fill
When designing a CNG fuel station
first the question of a suitable filling
mode must be clarified
If the opportunity exists of filling all vehicles of
fleet over a longer period of time one can consider the
purchase of a Slow-Fill system. Generally this is suitable
for smaller vehicle fleets (5-7 vehicles), which can
be filled at an in-house depot fuel station in the available
schedule intervals or large petrol stations for refuelling
bus fleets with more than 20 coaches.
During Slow-Fill tanking the compressor pumps, the compressed
natural gas is applied directly into the vehicle tank
without intermediate storage.
By means of a filling coupling is attached to the compressor
station, the vehicle can now be filled with the delivery
quantity of the compressor station in a corresponding
period.
Fast Fill
If however the natural gas is intended to be sold to
third parties or a large number of vehicles is intended
a Fast-Fill fuel station should be selected.
Here the compressed gas is first stored in a triple storage
rack, before it is filled into the vehicle tank by flowing
through the natural gas filling post. Generally filling
times of 1 to 2 minutes (80l cylinders) are attained.
In this instance however the maximum available gas quantity
in the triple storage rack must be taken into consideration
when filling vehicles as described under storage systems.
Daily Gas Requirements
To select the suitable compressor size first and foremost
the number of the vehicles to be filled daily is of great
importance.
When designing the system care must be taken that the
compressor already should have a daily minimum running
time of approx. 8-12 hours as both due to a technical
as well as an economic point of view long stand stills
should be avoided.
In a design of up to 12 hours compressor running time
per day correspondingly an increase in capacity of 50%
can be attained without additional components having
to be installed, although there is already a good exploitation
of the compressor system right from the start.
If due to a strong increase in fuelling demand, the gas
quantity required can not be supplied with the capacity
which will always be increased, thanks to the modular
extendibility of the Bauer systems.
In this instance depending on whether a compressor and
or a high pressure storage tank have to be added, an
additional module can be added simultaneously whereby
the delivery quantity or the gas quantity which can be
doubled from the high pressure tank for peak load refueling.
Irrespective of whether a compressor and storage unit
is selected from the MFS, CFS or CTA series with regard
to the expanding CNG market the modular extendibility
is always an economical solution for a system which is
always optimally exploited.
Pre-Pressure in the Gas Line
Another important aspect is the use of pre-pressures
in the gas networks.
Through the direct, non-adapted utilisation of the pre-pressure
actually present the specific power drain of the compressor
and thus the operating costs of the compressor system
are reduced as less energy is needed to compress the
natural gas which has already been pre-compressed.
When working with pre-pressure however the expected daily
running time of the compressor should be decisive as
when using booster systems higher deliveries of the compressor
generally result due to the higher gas input.If on using
a booster a daily running time of only a few hours results
a pre-pressure reduction which is also appropriate due
to service of capital reasons.
Also an adaptation of the gas input pressure to the maximum
permissible compressor input pressure can be useful in
so far as high connection costs to a high pressure supply
network is to be expected with a lower gas delivery potential.
An approximate reference value to be considered is a
direct, unadjusted pre-pressure utilisation at gas quantities
to be provided daily for vehicle refueling of approx.
1000 m³ and more.
Depot or Public Refueling
An additional aspect to be clarified in the type of refueling
is with regard to the group of customers
In the case of a depot refueling mainly vehicles belonging
to the company are refueled whereby a limited supply
is also possible to third parties. In these types of
cases a simple dispenser with automatic tank data recording
can be selected as these stations are usually operated
without any service personnel.
If the refueling system is to be integrated in a public
access gas station such as ARAL, ESSO etc. a filling
post must be used which is also available from Bauer
and can be connected with the common interface protocols
of the different cash till systems.
 Technical Data
CNG-/Natural gas
All system components of a CNG fuel
station such as compressor and tank unit,
gas dryer systems, filling priority and
sequential refueling controls as well as
filling systems are developed and produced
at Bauer and coordinated to run smoothly
together.
Outdoor Natural gas Compressor Systems
Outdoor
 Our
basic modules have been designed with maximum
flexibility in mind. If the demand for
CNG rises, storage cylinders can simply
be added.
Other strong points of the MFS and CFS units are the
maintenance-friendly design, low sound level and the
robust outdoor housing.
Mini
Fuel Station (MFS)
The Mini Fuel Station is the best
seller in Bauer’s product range of
atmospheric suction machines. Although
it was only launched on the market in 1997
more than 100 units had already gone into
operation by the year 2000.
 The MFS series is a reasonably priced starter model for
CNG vehicle fuel stations: with reasonable acquisition
and maintenance costs, compact dimensions, it is reliable
and maintenance friendly.
In keeping with market demands and as part of its on-going
product maintenance and improvement Bauer revised the
concept of the MFS series in 2000, a new PLC control
system was developed and the compressor system was integrated
in a compact concrete structure.
Technical
Data
Compressor
model |
Intake pressure
range
bar ü |
Capacity at **
250 bar
m³/h |
Number of
compressor
stages |
Power drain
kW * |
| MFS 120 - 5,5 |
0,01
0,3 |
12,6
16,9 |
3 |
4,0
5,2 |
| MFS 15.2 - 13 - 2 |
0,01
0,3 |
34,7
43,7 |
4 |
10,0
12,9 |
| MFS 15.4 - 13 - 2 |
2,0
4,0 |
30,0
51,5 |
3 |
7,4
12,4 |
Power
drain at 250 bar end pressure
** related to 1013 mbar, 20°C |
Outdoor Natural
gas Compressor Systems
 Mini
Fuel Station Compact (MFS Compact)
This system was especially designed by Bauer for filling
material handling vehicles (fork lift trucks) or in-house
fleet vehicles. Of course it can also be used for operating
natural gas vehicles in publicly accessible fuel stations.
The basic difference to the Mini
Fuel Station series is the inclusion of
a high pressure storage tank with 24 high
pressure cylinders each with 80l geometric
volume within a joint concrete enclosure.
This means that a large quantity of compressed
natural gas is available for fast fill
fuelling even at low compressor output
enabling the filling time to be reduced
to a minimum compared with a traditional
slow fill fuelling station.
Technical Data
Compressor
model |
Intake pressure
range
bar ü |
Capacity at **
250 bar
m³/h |
Number of
compressor
stages |
Power drain
kW * |
| MFS 120 - 5,5 |
0,01
0,3 |
12,6
16,9 |
3 |
4,0
5,2 |
| MFS 15.2 - 13 - 2 |
0,01
0,3 |
34,7
43,7 |
4 |
10,0
12,9 |
| MFS 15.4 - 13 - 2 |
2,0
4,0 |
30,0
51,5 |
3 |
7,4
12,4 |
*
Power drain at 250 bar end pressure
** related to 1013 mbar, 20°C |
 Compact
Fuel Station DUO, small (CFS-DUO)
The basic version of the CFS-DUO
series is intended for initial operation
with 1 compressor and 1 storage system.
If the amount of compressed natural gas
to be provided daily to refuel vehicles
exceeds the maximum capacity of the compressor,
the CFS-DUO series can be easily extended
with a second compressor and in the event
of the filling peaks increasing, with
a second storage rack tank (integrated
in a flange-mounted concrete enclosure).
Natural
gas compressor for atmospheric and
increased intake pressure range for
use in the CFS DUO series, small
Compressor
model |
Intake
pressure
range
bar ü |
Capacity
at **
250 bar
m³/h |
Number
of
compressor
stages |
Power
drain
kW * |
| C 120 - 5,5 |
0,01
0,30 |
12,6
16,9 |
3 |
4,0
5,2 |
| C 15.2 - 13 |
0,01
0,30 |
34,7
43,7 |
4 |
10,0
12,9 |
| C 22.0 - 30 |
0,01
0,30 |
58,0
75,1 |
4 |
18,8
22,3 |
| C 23.1 - 37 |
0,01
0,30 |
76,2
96,6 |
4 |
22,6
29,5 |
| CBK 15.4 - 13 |
2,0
4,0 |
30,0
51,5 |
3 |
7,4
12,4 |
*Power
drain at 250 bar end pressure;
** related to 1013 mbar,
20°C |
Outdoor
Natural gas Compressor Systems
 Compact
Fuel Station DUO, large (CFS-DUO)
In contrast to the CFS-DUO series,
small, this series was designed for compressors
with higher capacities and/or larger
gas input pressure ranges. The compressors
available in this series are equipped
with gas/water heat exchangers for the
intermediate and after cooling. The heat
transfer to the environment takes place
through a water/air cooler set installed
on the building roof.
In particular this type of cooling
a sound emission level under 60 dB(A)
is attained even for larger compressor
systems without additional sound insulation
measures
 Natural
gas compressor for atmospheric intake
pressure range for use in the CFS
DUO series, Large
Compressor
model |
Intake pressure
range
bar ü |
Capacity at **
250 bar
m³/h |
Number of
compressor
stages |
Power drain
kW * |
| C 25.0 -
45 |
0,01
0,30 |
109
141 |
4 |
39,0
43,0 |
| C 28.0 - 75 |
0,01
0,30 |
180
235 |
4 |
56,0
73,0 |
| C 28.0 - 90 |
0,01
0,30 |
225
293 |
4 |
69,0
89,0 |
*
Power drain at 250 bar
end pressure;
** related to 1013 mbar,
20°C |
Natural
gas compressor for increased intake
pressure range for use in the CFS
DUO series, largeCompressor series
CBK22.xx
| System type |
Intake pressure
range
bar ü |
Capacity at
**
250 bar
m³/h |
Number of
compressor
stages |
Power drain
kW * |
| CBK 22.10 |
min. 1
max. 3,5 |
58
141 |
4 |
16,2
33,6 |
| CBK 22.11 |
min. 3
max. 8 |
53
135 |
3 |
13,5
26,0 |
| CBK 22.12 |
min. 6
max. 11 |
83
148 |
3 |
17,5
26,1 |
| CBK 22.13 |
min. 8
max. 14 |
93
160 |
3 |
18,8
28,2 |
| CBK 22.14 |
min. 13
max. 35 |
79
212 |
3 |
15,5
26,3 |
* Power drain at
250 bar end pressure;
** related to 1013 mbar, 20°C |
 Compressor
series CBK28.xx
| System type |
Intake pressure
range
bar ü |
Capacity at
**
250 bar
m³/h |
Number of
compressor
stages |
Power drain
kW * |
| CBK 28.21 |
min. 3,0
max. 4,5 |
206
302 |
3 |
51,0
69,0 |
| CBK 28.22 |
min. 4,5
max. 10 |
212
437 |
3 |
49,0
80,0 |
| CBK 28.23 |
min. 9
max. 16 |
225
425 |
3 |
43,0
67,0 |
| CBK 28.24 |
min. 15
max. 35 |
267
670 |
3 |
43,5
77,0 |
*
Power drain at 250 bar end pressure;
** related to 1013 mbar, 20°C |
Indoor Natural
gas Compressor Systems
 CTA
Series
The natural gas compressors of
the CTA series are housed in a noise
insulating metal enclosure. These systems
are however solely designed for indoor
use.
Basically these compressor systems
contain the same compressor types as
the CFS series, including booster systems.
Of course, all the storage and filling
systems available in the delivery range
can be combined with the compressor
models of the CTA series.
It is imperative that the electrical
plant control system is installed in
a non-ex, gas tight room separate from
the compressor system.
 Accessories
for CNG Filling Stations
Accessories
The Optimal
Refueling Accessories for Economic
Operation
Bauer Kompressoren offers
you an extensive range of components
and accessories for your compressor
unit.
Contact us and find out
how Bauer products can be optimally
integrated in your production process.
Accessories
for CNG Filling Stations
 Storage
Systems
In most application
cases so-called triple storage
racks are used as an intermediate
storage for fast-fill fuel
stations and consist of three
individual partial storage
tanks: the top, middle and
bottom rack.
 These racks house a different number of pressure containers
which however are assembled together in one rack.
Technical
Data
| |
B800 |
B1920 |
B2000 |
B2400 |
| Installation
versions |
outside
/ inside |
| Number
of storage cylinders |
10
units |
24
units |
25
units |
30
units |
| Content
per storage cylinder |
80
l |
80
l |
80
l |
80
l |
| Geometric
total content |
800
l |
1920
l |
2000
l |
2400
l |
| Gas
volume stored at 300 bar (250 bar) |
Approx.
279 m³
(232 m³) |
Approx.
670 m³
(557m³) |
Approx.
697 m³
(580 m³) |
Approx.
837 m³
(697 m³) |
| Compressibility
factor |
0,86 |
0,86 |
0,86 |
0,86 |
| Gas
volume available at 300 bar (250
bar) |
Approx.
97 m³
(81 m³) |
Approx.
234 m³
(195 m³) |
Approx.
244 m³
(203 m³) |
Approx.
293 m³
(244 m³) |
| Exploitation
factor |
Approx.
35 % |
Approx.
. 35 % |
Approx.
35 % |
Approx.
35 % |
| Rated
operating pressure |
300
bar |
300
bar |
300
bar |
300
bar |
| Test
over-pressure |
450
bar |
450
bar |
450
bar |
450
bar |
 Priority
and Order Controllers
The filling priority
control serves for the priority
refuelling of the triple rack storage
system usually used. In the process
the compressed gas flow coming from
the compressor and gas treatment system
is first led into the top rack.If this
attains the maximum top value set,
the priority refueling control then
guides the gas flow into the middle
rack and finally to the bottom rack
| Bauer
offers the two systems shown
below: |
| • |
The VR250
is primarily used for refuelling
cars |
| • |
The VRÜ300
is used for large refuellingquantitiesoflorry/busrefuellingintheshortest
removal time |
Of course both systems can
be extended for the operation of
natural gas fill posts with 2 mass
flow meter facilities.
Accessories for CNG Filling Stations
Fill
Stations
Filling Equipment: Dispensers
The use of the dispensing equipment determines whether
a dispenser or fill post is used.
 The dispenser series FP is frequently
used in natural gas fuel stations in depots, especially
when the fuel stations are not continuously manned. By
using a filling machine activated using a station card
vehicles can be filled by the drivers themselves. The
refueling data invoicing then in most cases takes place
by using a refueling data processing program with invoicing
to the customer.
| Bauer
has several types on offer depending
on which version is required: |
| • |
Dispensers
without mass flow meter (car, bus) |
| • |
Dispensers with
mass flow meters (car, bus), can
be calibrated in connection with
an automatic vending machine |
Filling
 For operating a public fuel station the use of a fill
post (in contrast to a dispenser without flow mass meter)
is absolutely imperative due to statutory calibration
reasons.
On the display the unit price, quantity is refilled as
well as the final price are displayed simultaneously.
The posts can be used both for refueling cars as well
as buses and are available depending on the fuel station
(ARAL, ESSO etc.) in the suitable colour and with the
corresponding logo.
Generally the fill post computers are directly connected
to the cash till system in the fuel station shop so that
the familiar refuelling procedure is the same as for
liquid fuels. As required the fill post can also be operated
in connection with an automatic vending machine (EC,
VISA etc.).
Accessories for CNG Filling Stations
Refuelling
Data Recording
 For a planned invoicing through automatic vending machines
connected with fill posts/dispensers all the necessary
refuelling data for invoicing the end customer can be
obtained by modem with a relevant refuelling software
to the operator’s own computer system (also GSM).
For this purpose Bauer offers two automatic vending machines
which have been designed for sole operation with station
cards or also credit card operation and are especially
equipped with their own interface protocol for our fill
post program. A wide range of accessories for data back
up and EDI supplements the refuelling data recording
product range.
Accessories for CNG Filling Stations
Data Transmission
- EDI
 Knowing about the current
operating status of a natural gas refuelling
system, whether it is in operation, on
standby, disturbance or other important
information such as the number of current
refuellings, gas quantity tanked, gas pressures
in the triple track storage system etc,
is a demand placed by fuel station
operators which is gaining more importance.
For EDI Bauer supplies data transmitters both for transfer
through modem and the standard telephone network (ISDN)
as well as for EDI through wireless modem and GSM network.
Both EDI systems have the same equipment features and
it informs the control room automatically every time,
there is a system disturbance and/or reports the current
operating status of the system twice a day at freely
programmable times. Individual customer-specific parameters
can also be monitored following consultation with the
system operator.
Accessories for CNG Filling Stations
 Additional
Accessories
Bauer offers a reasonably priced external operating
status display for transferring the system status
of the natural gas fuel station as minimal information
to the station shop or an external location. This status
display is connected through hard wiring to the PLC control
system and shows the shop personnel the following disturbances:
| • |
Gas
alarm |
| • |
Emergency
off button pressed (fill post) |
| • |
Compressor
collective fault |
As required the station operator can be easily informed
by phone to initiate correction measures.
Additionally the shop personnel also have an emergency
off button with which the entire CNG fuel station can
be shut down in the event of danger without the shop
personnel having to leave the shop.
As an additional accessory Bauer offers a fully automatic pressure
dew point monitoring especially for smaller
natural gas fuel stations. Once the desiccant used is
saturated the system automatically shuts down with a
display on the PLC control system. As a result there
is no risk of damp entering the triple rack storage system
and the downstream refuelling technology. This also guarantees
a disturbance-free operation of the system even in the
lowest ambient temperatures in winter.
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