Instrument and Plant
Compressed Air Systems
in Containers
www.kaeser.com

Container – Design – Installation
KAESER container solutions are tailored to individual customer needs and can be operated in temperature ranges from–50 °C to +45 °C. Ambient temperatures over +45 °C require alternative turnkey solutions which can be offered according torequirement. Low-temperature steels are used for temperatures below –50 °C.
KAESER guides its customers every step of the way from inquiry, design, order, factory approval, packaging, loading andtransportation to unloading and initial on-site start-up.
The compressor packages are manufactured according to specific customer and country requirements.
KAESER customers have the option of installing the ready-to-use compressor station(s) on-site thereby reducing both costs
and time. The systems are tested at the KAESER plant in Austria where the agreed operating parameters are preset. If thecompressed air installation comprises multiple containers, we ensure that they can be operated as a single unit, as well as
in combination with one another. System operation, together with the proven SIGMA AIR MANAGER 4.0 master controller,
guarantees best possible load efficiency (see image below). This type of installation reduces on-site compressor installation
time to a minimum. In its Austrian plant, KAESER is able to operate and test multiple containers in combination and can evenemulate system communication with a simulated control centre.

Planning
The entire planning process for the container system is implemented at KAESER Linz by specially trained in-houseengineers. Construction and system layout are performed
using the very latest 3-D planning tools in close partnership with you.

During this phase, the prevailing ambient conditions –such as temperature, dust exposure, humidity and othercontaminants – are scrutinised in addition to the required operating parameters. Following the successfulplanning phase, the transportation conditions are checked.
This involves route planning, access, unloading and onsite installation conditions.
Working drawings, pipe diagrams, production drawings
and wiring diagrams are all created by the KAESER
engineers.

2Container design
The containers are insulated steel units and feature ISO
container corners. The containers are statically designed
in such a way that they can be lifted at the upper container
corners. They are completely piped and wired and include
a control cabinet with power sub-distribution, an automatic ventilation system, a heater, lighting and emergency
lighting. The design is implemented in accordance withcustomer requirements and requests.
KAESER uses insulated containers that are specially
produced for each specific application.

Insulated containers ensure far better thermal conditions
within the container than non-insulated containers andprevent condensation from occurring on the inside. A
further advantage is sound reduction and the minimisationof acoustic emission to the environment. All openings are
reinforced to ensure that the structural strength of the container is maintained. Rain protectors are installed above
the openings in order to prevent rainwater ingress.
External dimensions of L= 15,000 mm, W= 3,500 mm and
H= 3,700 mm are available without the need for further
planning. For larger dimensions, information regarding the
installation location is necessary in order to allow a transportation feasibility check during the quotation phase.

3

11

2
7

4

1

5

3

10

1 Galvanised sheet steel

5 DC desiccant dryer

9 Filters

2 Emergency lighting

6 Aquamat

10 Electric heater

3 700 mm escape route7 Control cabinet

11 Anchoring point

4 CSD compressor

8 Pipes

6

Container 3-D planning order for the oil and gas industry in England

Equipment
Exterior paint finish
The exterior paint finish is applied as per KAESER
standard with a 120 µm thickness of the dry layer; walls
are painted in broom yellow RAL 1032 and the frame inanthracite grey RAL 7016. Upon customer request, a different paint colour, thickness of the dry layer and requested layer structure can be applied.

Internal corrosion protection
The insulated standard container is lined on the inside with
galvanised sheet steel. The stud plate floor is painted inlight grey RAL 7035; the floor paint layer thickness is 80µm.

Structural analysis evaluation
A certified structural analysis evaluation can be provided
in English or German as required. However, this must be
agreed upon prior to placing of the order. KAESER suppliers implement an internal structural analysis inspection forevery order.

4

Container safety-related design
features
The container interior is equipped with emergency lighting
above the personnel doors in order to enable safe exitfrom the container in the event of a power failure. The
emergency lights provide illumination for approximately
1 ½ hours.
The equipment is installed in the container in such a way
as to allow a clear 700 mm wide escape route.
The personnel doors are equipped with panic locks which
can be opened from the inside even when locked. Personnel can therefore exit the container at any time.
The necessary anchoring points for the equipment, piping
and electrical equipment are already defined during thecontainer construction phase.
Smoke and gas warning systems can be installed uponrequest.

Pipework

Electrical equipment

The pipework is implemented in accordance with PED

The containers feature EN 60204 compliant control cabinets and are fully wired; further features include interior
lighting, electric heaters for frost protection and emergency
lighting.

97/23 EC or ASME:• Galvanised pipework with screw or grooved design.
• Stainless-steel pipework with welded or grooved design.
KAESER Linz is a certified specialised welding company
and is independently able to weld and inspect the mostvaried of piping materials in its in-house workshop.
Pipe pressure stages PN 10 or PN 16 and PN 45.
Leakage tests and water pressure tests are carried out inthe plant and are monitored by the QM system.
Based on a type approved by the German TechnicalInspection Association (TÜV), the pipework may be independently certified in accordance with PED 97/23 EC.

Wiring is implemented with flexible light plastic-sheathedYSLY-JZ type cables in galvanised cable ducts and inplastic pipes for small consumers.
The system as a whole undergoes an internal test run in
Linz under the specified conditions (as far as is possible)
and only leaves the plant following a successful test run.

Oil leak tightness of container
If necessary for environmental or other reasons, thecontainer floor can be designed as an oil-tight pan.

Other pipe materials are available upon request.

CERT

IFIED

Container 3-D planning for filter and desiccant dryer pipework

8

9

9

5

SOUNDPROOFEDCONTAINER

SIGMA AIR UTILITY

SIGMA PET AIR

Examples of container applications

6

Container solutions are used in awide range of areas, e.g. for pressure increase of nitrogen from 6 to
28 bar with boosters, for instrument
and/or shop air containers, but also
as booster solutions for PET applications up to 45 bar. These PET
solutions are listed on the website
at: Kaeser.com/Products/Reciprocating compressors/

Information regarding SIGMA AIRUTILITY compressed air contracting
can be found on the KAESER website at: Kaeser.com/Products/SIGMA AIR UTILITY operator model.
For SIGMA AIR UTILITY applications, the compressed air supply is
installed in one or more containers.
Only the actually incurred compressed air costs are calculated.

In order to ensure compliancewith applicable sound emissions
regulations, it is possible to equip
the container with appropriate
soundproofing. During the planningstage, local conditions are taken
into consideration to achieve themost effective sound level reduction. The illustrated example showsa container on a flat roof at a heightof approx. 12 m; the required soundlevel at a distance of 10 m is 40
dB(A). The sound level measured at
the Linz plant was in fact lower than
the required sound level.

CERT

IFIED

Test run and training
Internal test run

Training in Linz or on-site

Prior to delivery to the customer, the entire system undergoes an internal test run at the plant in Linz, under the
specified conditions, and is only delivered following a successful test run. The system test run is performed by thetechnician responsible for the initial on-site start-up – this
therefore ensures complete familiarity with every system
detail. The test runs can also be performed at different
voltages: 690 V 50 Hz, 480 V 60 Hz, 440 V 60 Hz, 400 V
50 Hz, etc.

Upon request, we provide training in Linz or on-site for theoperator personnel. The duration depends on the scopeof the training. The training is held in English or German
and training documentation is also available in English or
German.

Factory Acceptance Test (FAT)
Upon request, KAESER will also perform Factory
Acceptance Tests (FAT) in the presence of the customer
and/or an independent expert. During these tests, thecontractually agreed parameters are checked and alsochanged, if requested. Depending on the agreement andthe scope, the time period for a FAT is one to 8 days andlonger.
Following a successful FAT or internal test run, and uponcustomer approval, the systems are released for packaging and final cleaning.

7Documentation and approvals
Documentation
Comprehensive documentation for the entire scope ofdelivery in accordance with Machine Directive 2006/42/EC
is included in English or German. However, the documentation can also be provided in other languages as required.

Quality management: ISO 9001:2008
KAESER Linz has been certified in accordance with ISO
9001:2008 and is inspected annually by the LGA-Intercert
institute. In addition to standard quality management, wehave also obtained ISO 29001 approval for the oil and gas
industry.

International approvals forthe containers
The following approvals exist for the containers as finishedmachines:
For the European market: CE approval pursuant
to Machine Directive 2006/42/EC and Pressure
Equipment Directive PED 97/23/EC module B+D.
For the American market UL Pre FES.
For the Russian market: EAC in accordance withvalid TR CU Rules from 2015. Technical passport,
safety expertise and TR 010/2011, 004/2011 and
020/2011.
Complete documentation is available in English or
German. Documentation can be provided in otherlanguages as agreed upon request.

8

Installation and commissioning
Commissioning process following
successful on-site setup
As described below, it takes on average 2-3 days frominstallation of the container until initial commissioning. The
key prerequisite is that the supply cables for the container,
the compressed air line and the condensate line are located at a distance of 1-2 m from the container installation
location. The external wiring and piping of the container isthe customer’s responsibility.
All internal approvals for the initial commissioning of thecontainer must be available.
Day 1: Completion of cable connection comprising
installation and connection of the prepared cable in thecontrol cabinet and container system. This work is to be
performed on-site. The power supply must be provided
by the customer.

Day 3: Inspection of the entire system for possible transport damage, and checking of the cable connections in
the container system control cabinet. Once the check has
been performed and the safety of the system has beenverified, the compressor station is commissioned stepby-step by the KAESER technician responsible for initialstart-up.

On-site commissioning with inclusion of the local
branch office or partner
On-site commissioning is performed by the KAESER
technician responsible for initial start-up who has been
involved with the system from the outset at the KAESER
plant through to delivery. The local KAESER branch officeor KAESER partner is involved in the system commissioning phase.

Day 2: Completion of the remaining 1-2 m of compressed
air line and condensate line. This work is to be performed
on-site.

Key hand-over to customer

9

Shipping
Packaging and final cleaning•

The packaging is suited according to the applicable
shipping method.

•

The systems undergo a rigorous final
cleaning process prior to the delivery.

•

The shipment is released following final
cleaning approval.

•

The systems are packed in single-use plastic sheetingfor standard transportation by lorry.

•

Seaworthy packing crates are used for sea transport.

•

Single-use plastic sheeting is used for air transport.

•

Packaging takes place at the plant in Linz.

•

Information required for transportation and loading is
attached on the outside of the packaging: Centre ofgravity, attachment points, chain angles, address.

Loading
The containers are loaded using 32-ton capacity in-door
cranes in the installation hall.

Transportation
Transportation is performed by KAESER as requested byroad, sea or air, or a combination thereof. Route planningand the necessary approvals are organised by the respective shipping company.

UnloadingOn-site unloading of the systems is the customer’s responsibility. KAESER provides the necessary documentation,such as centre of gravity drawings, unloading drawing withbrackets for the hoisting devices and attachment points.
The container should be placed on an even and horizontal
foundation.

10

11

UnloadingTransportation Loading

PackagingSkid solutions
For oil and gas applications and for Sigma PET Air Packages. We will gladly design a tailored skid solution for you
that meets your exact needs.
KAESER skid solutions for ambient temperatures of over
45 °C and up to 60 °C have already been implemented in
the United Arab Emirates, Tunisia, Oman, Saudi Arabia, Qatar, the Philippines, Syria, Malaysia, etc. and aremainly used in the oil and gas industry. These systems are
modified in accordance with oil and gas requirements, e.g.
for installation under a flying roof with specially developed
sand separators for the cooling and compression air.

KAESER skid solutions are suitable for oil and gas applications with ambient
temperatures of up to 60 °C, high sand load and for installation under a flying
roof.

12

KAESER Sigma Pet Air Packages
For ambient temperatures up to 45 °C; systems are installed in Japan, Pakistan, Australia, Nigeria, Iraq, Afghanistan, Ethiopia, Azerbaijan, Mexico, Somaliland, Angola,
Venezuela, Bangladesh, Tunisia, Zambia, Tanzania, Lebanon, Vietnam, Greece, Mongolia, Zimbabwe, Chile, Kenya,
New Zealand, Dominican Republic and Aruba. (See mapon the next page)
SIGMA PET AIR Packages

Countries with Kaeser container solutions

References
KAESER has been successfully meeting the specificneeds of the most varied sectors of industry for decades.
Renowned company names such as Linde, Shell, Air
Liquide, Magna or Techno Alpin confirm KAESER’s exceptional expertise.
KAESER’s special focus is on customised solutions andthe resulting innovations.
With its 25 years of experience in plant engineering andmanufacturing – during which time over 100 container
systems, as well as approx. 200 base frame systems foroil and gas applications and 250 base frames systems for
PET applications for pressures up to 40 bar have been
produced for a wide range of industrial sectors –KAESER’s professional expertise grows ever stronger
through close partnership with its customers. This results
in innovative solutions based on proven technology.

Countries where you can find KAESER container
and base frame solutions:
Germany, Austria, Switzerland, Croatia, Slovenia, Italy,
Belgium, Holland, England, Ireland, Sweden, Finland,
Kazakhstan, Russia, Moldova, Ukraine, Poland, Hungary,
Romania, Bulgaria, Turkey, Malta, Jordan, South Africa,
Thailand, USA and Argentina.
Contacts have already been established in many other countries: providing fast and effective local support,
KAESER Linz is closely networked with individual country
subsidiaries and authorised KAESER dealers.

13

KAESER Linz – The Competence Centre
KAESER Linz has been building customised solutions
since 1990 and has grown to become a competence
centre for base frame and compressed air container
solutions. The customer-tailored solutions are built in twoareas covering a floor area of approximately 2,200 m².
We employ qualified engineers in the areas of electronics,
piping and ventilation who implement these solutions.
Multiple systems are constantly produced in parallel andare supervised by the respective engineers and foremen.
Two testing bays are available for performing system test
runs and checks. Final cleaning and packaging takes
place inside the plant halls – not outside. The production
process is monitored by the project engineers and ourquality management system every step of the way rightup to, and including, loading. Transportation, logistics andcustoms clearance are organised by our internal Logistics
department. The project engineer and the Documentation
department are responsible for documentation for therespective product.
Contact: info.austria@kaeser.com

Sales centre:● Linz● Wr. Neudorf● Hart bei Graz
● Wiesing● Weiler

Linz
Wr. Neudorf

Wiesing
WeilerHart bei Graz

14

Certificates
Certificate

Certificate

AUSTRIA

Standard

ISO 9001:2015

Standard

ISO 14001:2015

Standard

ISO 45001:2018

Certificate Registr. No.

01 100 2100058/48

Certificate Registr. No.

01 104 2100058/48

Certificate Registr. No.

01 213 2100058/07

Organization:

Organization:

Proof has been furnished by means of an audit that therequirements of ISO 9001:2015 are met.
Validity:

The certificate is valid in conjunction with the main certificate
01 100 2100058 from 2022-11-01 until 2025-10-31.

2022-09-26
TÜV Rheinland Cert GmbHAm Grauen Stein · 51105 Köln

www.tuv.com

Site:

c/o KAESER KOMPRESSOREN Ges.m.b.H.
Dallingerstr. 84031 Linz
Austria

Scope:> Engineering, sale and servicing of the following product range:
Rotary screw and reciprocating compressors for compressed
air and vacuum, blowers, portable compressors, compressed
air dryers, compressed air filters, condensate drains, condensate
separators, air receivers, compressor controllers and compressed
air management systems, teleservice, heat recovery systems,
air utility systems> Engineering and assembly of customer-specific compressed
air solutions and nitrogen generation systems
Proof has been furnished by means of an audit that therequirements of ISO 14001:2015 are met.

Validity:

The certification body of TOV AUSTRIA SERVICES GMBH
certifies that

KAESER KOMPRESSOREN Ges.mbH
DallingerstraBe 8
4031 Linz, Austria

KAESER KOMPRESSOREN SE
Carl-Kaeser-Str. 26
96450 Coburg
Germany

The certificate is valid in conjunction with the main certificate
01 104 2100058 from 2022-11-01 until 2025-10-31.

2022-09-26
TÜV Rheinland Cert GmbHAm Grauen Stein · 51105 Köln

www.tuv.com® TÜV, TUEV and TUV are registered trademarks. Utilisation and application requires prior approval.

> Engineering, sale and servicing of the following product range:
Rotary screw and reciprocating compressors for compressed
air and vacuum, blowers, portable compressors, compressed
air dryers, compressed air filters, condensate drains, condensate
separat ors, air receivers, compressor controllers andcompressed air management systems, teleservice, heat recovery
systems, air utility systems> Engineering and assembly of customer-specific compressed
air solutions and nitrogen generation systems

Site:

c/o KAESER KOMPRESSOREN Ges.m.b.H.
Dallingerstr. 84031 Linz
Austria

Scope:> Engineering, sale and servicing of the following product range:
Rotary screw and reciprocating compressors for compressed
air and vacuum, blowers, portable compressors, compressed
air dryers, compressed air filters, condensate drains, condensate
separators, air receivers, compressor controllers and compressed
air management systems, teleservice, heat recovery systems, airutility systems> Engineering and assembly of customer-specific compressed
air solutions and nitrogen generation systems
Proof has been furnished by means of an audit that therequirements of ISO 45001:2018 are met.

Validity:

has met all necessary quality requirements for
welding according to

EN ISO 3834-3

This certificate is valid for the following products or service ranges:
Manufacturing, service of air and inert gas compression
and treatment plants

Date of expiry:
Certificate No.:

HZ-00591-19-FOE

Failure to meet all these necessary requirements as defined in the annex to this certificate will spoilt this document!
The certificate keeps valid, if the TOV AUSTRIA SERVICES GMBH performs the annual surveillance.

The certificate is valid in conjunction with the main certificate
01 213 2100058 from 2022-11-01 until 2025-10-31.

2022-09-26
TÜV Rheinland Cert GmbHAm Grauen Stein · 51105 Köln

Leonding
PLACE

www.tuv.com

TUV AUSTRIASERVICES GMBH

Deutschstra�e 10
A-1230 Wien

Wittmann Gera
Wirtsch.-lng.
DATE

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CERTIFICATION BODY

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046999-18-4

Zertifikat
Die
Notifizierte Stellenach Druckgeräterichtlinie
TÜV SÜD Landesgesellschaft Österreich GmbH
Franz Grill Straße 1, Arsenal, Objekt 207
A-1030 Wien

bescheinigt hiermit,
dass das Unternehmen

Kaeser Kompressoren GmbH
Dallingerstraße 84031 Linz, Österreichein Qualitätssicherungssystem nachRichtlinie 2014/68/EU,
Anhang III,
Modul D
eingeführt hat und anwendet.

Mit dem durchgeführten Audit am 10.01.2022 wurde der Nachweis erbracht, dass die
betreffenden Anforderungen erfüllt sind.
ZVD-419 Rev00 06/2020

c/o KAESER KOMPRESSOREN Ges.m.b.H.
Dallingerstr. 84031 Linz
Austria

Scope:@BCL@D009C73B.docx

Site:

CERTIFICATE

Organization:
KAESER KOMPRESSOREN SE
Carl-Kaeser-Str. 26
96450 Coburg
Germany® TÜV, TUEV and TUV are registered trademarks. Utilisation and application requires prior approval.

KAESER KOMPRESSOREN SE
Carl-Kaeser-Str. 26
96450 Coburg
Germany® TÜV, TUEV and TUV are registered trademarks. Utilisation and application requires prior approval.

TiJV

Certificate

Das Zertifikat Nr. 0531-PED-ModD-0800 wurde aufgrund des mit Erfolg durchgeführten
Audits erstellt.
Das Zertifikat ist gültig bis 09.12.2024
Der Hersteller ist daher berechtigt, die im Rahmen des Geltungsbereiches dieses
Qualitätssicherungssystems hergestellten Druckgeräte bei der Kennzeichnung mit unserer
Kennnummer wie dargestellt zu versehen.

Wien, den 25.01.2022

Josef Kogler (Jan 31, 2022 10:40 GMT+1)
Notifizierte Stelle, Kennnummer 0531
(Dipl.-Ing. J. Kogler)

Bitte beachten Sie die Hinweise auf der zweiten Seite.

Tel.: +43 (0)5 0528 4400
Fax.: +43 (0) 5 0528 1077

Certificate

015
ISO 14001:2

Standardeg
Certificate R

istr. No.

058/4801 104 2100n:
Organizatio
REN
OMPRESSO
KAESER K
26
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ae
Carl-Kg
96450 Cobur
Germany

Site:

Scope:SE

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c/o KAESE
8
Dallingerstr.
4031 Linz
Austria

Ges.m.b.H.

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15

The world is our home
As one of the world’s largest manufacturers ofcompressors, blowers and compressed air systems,
KAESER KOMPRESSOREN is represented throughout
the world by a comprehensive network of wholly owned
subsidiaries and authorised distribution partners in over
140 countries.
By offering innovative, efficient and reliable products andservices, KAESER KOMPRESSOREN’s experienced
consultants and engineers work in close partnershipwith customers to enhance their competitive edge
and to develop progressive system concepts that
continuously push the boundaries of performance andtechnology. Moreover, decades of knowledge and expertisefrom this industry-leading systems provider are madeavailable to each and every customer via the KAESER
group’s advanced global IT network.

KAESER KOMPRESSOREN SE

P.O. Box 2143 – 96410 Coburg – GERMANY – Tel +49 9561 640-0 – Fax +49 9561 640-130
E-mail: productinfo@kaeser.com – www.kaeser.com

P-225ED Specifications are subject to change without notice. .2/22

These advantages, coupled with KAESER’s worldwide
service organisation, ensure that every product operates atthe peak of its performance at all times, providing optimal
efficiency and maximum availability.