CNG REFUELLING SOLUTIONS

Transcription

1 CNG REFUELLING SOLUTIONS INTELLIGENT AIR AND GAS TECHNOLOGY

2 01 SOLUTIONS Intelligent CNG Solutions With over 1000 CNG compressors supplied worldwide CompAir has been involved with the manufacture and installation of compressed natural gas refuelling systems since the early 1980 s. During this time CompAir has supplied to over 25 countries with stations in the UK, Germany, France, Netherlands, USA, Brazil, Malaysia, Korea, China and Bangladesh, and are the market leaders in Poland, Australia and Pakistan. CompAir meet the needs of a diverse range of customers through a series of modular, ready-to-run packages based around the Gazpack range of air and water cooled reciprocating compressors. The Gazpack series is designed to cover the full range of station types from pilot projects and small forklift fleets, through to high capacity public stations and large bus refuelling depots. Designed for flexibility and ease of installation, the Gazpack series is available in a wide range of packaging options. With advanced compressor design, extensive turnkey project experience and a truly local service capability, CompAir offers a Total Solution approach to CNG refuelling. COMPAIR IS A WORLD LEADER IN THE DEVELOPMENT OF MODULAR SYSTEMS FOR COMPRESSED NATURAL GAS REFUELLING WHETHER YOUR MOTIVATION IS ENVIRONMENTAL, FINANCIAL OR POLITICAL, COMPAIR HAS THE SOLUTION TO MEET YOUR NEEDS

3 SOLUTIONS 02 PROVIDING RELIABLE COMPRESSION SOLUTIONS SINCE 1898 The Gazpack range of CNG compressors is manufactured primarily at the state-of-the-art CompAir facility in Ipswich, England. The company moved from the original Reavell factory, established in 1898, to Reavell House in 2005 and enjoys enhanced manufacturing, test and paint facilities, as well as environmentally friendly water and oil recycling systems. Shanghai CompAir-Dalong HP Equipment Co. Ltd, a Joint Venture established in China in 2004, also designs and manufactures European quality CNG stations for the Chinese and Asian markets. CompAir is registered to ISO Quality Management System by Lloyds Register Quality Assurance and conforms to the requirements of the European Pressure Equipment Directive (Module H) where appropriate. Witness testing and certification by most major accreditation bodies, such as Lloyds Register and TUV, can be met on request. As a manufacturer of CNG systems, CompAir retains greater control over quality and technological improvements in the compressor package, and a dedicated team of highly experienced project and design engineers is able to customise the Gazpack range to meet specific customer needs. Combined with specialist partners who are carefully selected to provide quality ancillary equipment such as dispensers and dryers, CompAir is able to provide a complete and reliable solution to meet the customer's refuelling needs. COMPAIR MANUFACTURES QUALITY CNG COMPRESSION PACKAGES UNDER THE ISO QUALITY MANAGEMENT SYSTEM

4 0 SOLUTIONS Turnkey Solutions With over 25 years experience in the CNG industry CompAir has extensive experience providing project management assistance for turnkey projects. PROVIDING TURNKEY PROJECT MANAGEMENT FOR OVER 25 YEARS CompAir offers the expertise to develop a complete refuelling station, covering: Project feasibility Site suitability Planning and approvals process Station and equipment design Utility procurement Equipment manufacture Site preparation Installation Commissioning Training Station Design Station design is a critical part of any refuelling station project. The CompAir team of experienced sales managers and engineers can advise on all aspects of station design, taking into account the station type, fleet type and purpose, fill volume, site limitations, budget and other issues. Fast Fill Fast Fill stations primarily utilise gas drawn from a storage bank previously filled by the compressor, rather than direct from the compressor. The speed of fill is comparable to petrol or diesel and is typically found on public forecourts. This method is always used where the exact volume of gas in each vehicle must be quantified.

5 STATION DESIGN 04 Time Fill With time fill posts the vehicle is refuelled directly from the compressor without the need for storage cylinders. Refuelling is therefore slower and more suited for vehicles left overnight at a depot, such as buses. With time fill posts the quantity of fuel dispensed into each vehicle is not easily monitored and therefore time fill is unsuitable for public refuelling stations. Mother & Daughter The mother-daughter concept is a 'virtual pipeline' where natural gas is drawn and compressed from the pipeline at the Mother site and transported to the Daughter site by truck and trailer. This is usually used to service sites that are not located near a natural gas pipeline. Once at the daughter station vehicles can be filled directly from the trailer using a CNG dispenser. The mobile cylinders are filled to above 200 bar at the mother station but due to pressure drops during decanting, it is essential to have a compressor on site to ensure pressure in the delivery line remains above 200 bar. When the pressure in the trailer cylinders finally drops below 20 bar, the trailer is returned to the mother station for refilling. A daughter station will usually have several trucks and trailers working on a shuttle system. THE MOTHER-DAUGHTER CONCEPT IS IDEAL FOR SITES NOT ON A PIPELINE

6 05 MODULAR SOLUTIONS Modular Solutions THE GAZPACK RANGE IS A MODULAR READY-TO-RUN SYSTEM AVAILABLE IN A VARIETY OF CONFIGURATIONS, CUSTOM-BUILT TO MEET CUSTOMER SPECIFICATION. EXAMPLE A Skid mounted compressor and inlet train EXAMPLE B Skid mounted compressor and inlet train with cooling system EXAMPLE G Fast Fill Station - full turnkey project EXAMPLE F Time Fill Station - full turnkey project COMPAIR IS ABLE TO SUPPLY GAZPACK MODULES & ANCILLARIES TO MEET MOST CUSTOMER REQUIREMENTS

7 MODULAR SOLUTIONS 10 EXAMPLE C Bedplate mounted compressor and inlet train with cooling system, filtration and gas recovery EXAMPLE D Bedplate mounted compressor and inlet train with cooling system, filtration and gas recovery system contained within a weatherproof acoustic enclosure EXAMPLE E All Gazpack modular packages are available with stand alone ancillaries, including control panel, cascade storage and dispensers. SUPPLY ONLY SUPPLY & INSTALLATION FULL PROJECT MANAGEMENT

8 07 PRODUCTS Advanced Compressor Design Compact modular design provides a small footprint unit with maximum flexibility Well balanced compressor design, plus the use of anti-vibration mounts and flexible connections removes the need for special foundations and reduces vibration Individual, compression stage separation using CompAir designed high efficiency separators reduces moisture carryover between stages thereby increasing component life Gas recovery system means no loss of gas to atmosphere under normal operation Fully automatic controls are designed for simple, unmanned compressor operation Complete set of safety trips and indicators, all wired to explosion proof and intrinsically safe terminal boxes, which simplifies installation Installation is made quick and simple through the use of flexible connections and the single outlet manifold for all pressure safety valves. PRODUCT RANGE DELIVERY PRESSURE 250 BAR G Gazpack 70 Gazpack Gazpack 7 Gazpack 42 Gazpack 42 High Inlet* Gazpack 7 High Inlet Capacity (m /hr) 10 0 Gazpack 9 Gazpack 7 Gazpack 5 Inlet Pressure (bar g) *In Development NOTES TO TECHNICAL DATA: Ambient temperatures: -10ºC to 45ºC. Performance figures are typical and are not the full range available. Performance temperatures are based on gas inlet temperature of 20ºC and 15ºC cooling water temperature and referenced to 1.01 bar absolute. Flow rates (FGD) measured in accordance with ISO 1217:1996. Flow rates for radiator cooled packages will be reduced. Delivery pressure of 250 bar g is typical. Delivery pressures up to 50 bar g are available. Performances on electric motors are based on a 50Hz supply. Vehicle numbers based on 12 hour compressor running time at maximum capacity and typical cylinder capacity of 10m (forklift), 16m (car), 150m (bus).

9 PRODUCTS 08 Gazpack Series Perfect for forklift trucks Capacity (FGD) Inlet Gas Pressure 12 60m /hr to 0.4 bar g The Gazpack 5, Gazpack 7 and Gazpack 9 range offers a compact ready-to-run refuelling package. Contained within a weatherproof acoustic enclosure, the units include a 4 stage air cooled compressor, gas recovery vessel, filtration and control panel. These modular packages can also be combined with dispensers, storage and safe area controls. TECHNICAL DATA Model GAZPACK 5 GAZPACK 7 GAZPACK 9 Motor Power (kw) Compressor Speed (rpm) Inlet pressure (bar g) FGD Capacity (m 250 bar g delivery pressure * DIMENSIONS & WEIGHT Gazpack 5 745mm W x 1250mm D x 1925mm H 800kg 27 Gazpack 7 870mm W x 129mm D x 2045mm H Gazpack 9 970mm W x 1900mm D x 2260mm H 875kg 1,650kg *160 rpm GAZPACK 5 GAZPACK 7 GAZPACK 9 NUMBER OF VEHICLES FILLED IN A 12 HOUR PERIOD

10 09 PRODUCTS Gazpack Series 7 42 Ideal for medium sized refuelling stations Capacity (FGD) Inlet Gas Pressure m /hr to 6.8 bar g The Gazpack 7 and Gazpack 42 multistage water cooled compressor packages offer reliability and increased capacity for medium sized stations. As modular units, the Gazpack 7 and 42 can be supplied as simple skid mounted blocks through to fully packaged systems with cooling systems, recovery vessels and filtration within acoustic enclosures. Fully packaged Gazpack 7 with integral storage and control room. TECHNICAL DATA DIMENSIONS & WEIGHT Gazpack 7 minimum specification block 246mm W x 1415mm D x 147mm H 2,200kg Gazpack 42 minimum specification block 2424mm W x 1922mm D x 1418mm H,250kg Gazpack 7 or 42 with acoustic enclosure 2200mm W x 5500mm D x 2400mm H 8,000kg Model Motor Power (kw) Compressor Speed (rpm) Inlet pressure (bar g) ø 195 ø * GAZPACK 7 GAZPACK FGD Capacity (m 250 bar g delivery pressure GAZPACK 7 GAZPACK 42 *1500 rpm 1590 rpm ø 45kW 150 kw In development NUMBER OF VEHICLES FILLED IN A 12 HOUR PERIOD

11 PRODUCTS 10 Gazpack Series Recommended for large bus and truck fleets Capacity (FGD) Inlet Gas Pressure m /hr 1.0 to 18.0 bar g The Gazpack 50 and Gazpack 70 series multistage air cooled compressors offer larger capacities and higher inlet pressures for maximising gas mains pressure and thereby providing energy efficiency savings. These are modular packages with optional air blast cooling, gas recovery system, filtration, baseframe and weatherproof acoustic enclosure. Fully packaged Gazpack 70 with external storage and dryer. TECHNICAL DATA MODEL Inlet pressure (bar g) FGD Capacity (m /hr) Stages Compressor Speed (rpm) GAZPAC 50 (45 kw) GAZPAC 50 (12 kw) GAZPAC 70 (12 kw) GAZPAC 70 (225 kw*) DIMENSIONS & WEIGHT Gazpack 50 with acoustic enclosure 2400mm W x 5900mm D x 2400mm H 8,000kg Gazpack 70 with acoustic enclosure 2400mm W x 7250mm D x 2600mm H 12,000kg *Direct Drive Only 110 kw 250 kw GAZPACK 50 GAZPACK 70 NUMBER OF VEHICLES FILLED IN A 12 HOUR PERIOD

12 11 ANCILLARIES Ancillaries CompAir offers all the ancillaries required for a fully operational refuelling station: Storage Priority Panel Dispensers - fast fill and time fill options Controls Dryers Electronic access Remote access Gas detectors Dew point monitors Cascade storage systems A Fast Fill refuelling system provides gas on demand using a combination of the compressor and prepressurised storage to maximise a 200 bar fill for the vehicle. There are three key elements: Priority Panel, Cascade Storage (typically banks - High, Medium and Low) and Electronic Dispenser. The Priority Panel prioritises the use of gas from the compressor to the Cascade Storage: firstly to the High Bank, then the Medium Bank and finally the Low Bank. The Electronic Dispenser draws on gas from the storage in reverse order (Low, Medium, High) and finally directly from the compressor if demand has exceeded the storage capacity. This system maximises vehicle fill and station capacity and is recommended for public stations. Storage CompAir offer a variety of storage systems designed specifically to local standards. All vessels and cylinders can be designed to meet ASME, DOT and TPED specifications and are fully weatherproof removing the need for enclosures, although enclosures are available on request. STORAGE TYPICAL SPECIFICATIONS 80 litres water capacity per cylinder Compressor feed lines 12mm OD 16 stainless steel tubing & fittings Dispenser bypass line 16mm OD 16 stainless steel tubing & fittings Mechanical valves set storage bank filling priority Maximum working pressure 50 bar g Gauges fitted to compressor feed line and all storage bank lines Lightweight panel with flexible mounting options

13 ANCILLARIES 12 Dispensers A full range of electronic and manual dispensers are available, with simple manual operation or fully automatic dispensing with card access technology. TIME FILL POSTS Includes fuelling valve, pressure gauge, hose and connector assembly Cost effective with high reliability Unmanned operation once connected Can lower energy costs through use of cheaper off peak energy rates No need for storage systems Ideal for depot based overnight refuelling with modest daily mileage Dryers Natural gas vehicles require high quality clean gas to ensure long life and minimum maintenance. CompAir offer a range of dryer systems to ensure full protection for the vehicle and the refuelling station. Options include both Low Inlet dryers (precompression) and High Inlet dryers (post-compression). High Inlet dryers are available as static or re-generative systems. The choice of dryer is affected by dew point, inlet pressure and compressor flow rate. MANUAL FAST FILL DISPENSERS Single or dual hose designs with Breakaway safety connections NGV1 or NGV2 nozzles available 1 bank sequencing options Ideally suited for single car dispensing or as a backup dispenser at a refuelling depot ELECTRONIC FAST FILL DISPENSERS Flow rates up to 80kg/min Single or dual hose designs with Breakaway safety connections NGV1 or NGV2 nozzles available Coriolis mass flow meter Explosion proof and intrinsically safe electronics 1 bank sequencing options Suitable for electronic card access and payment systems and stations with high speed filling requirements Controls CompAir is able to provide a full range of control systems from simple manual controls to complete systems, with optional PLC, designed for unmanned operation. Control systems can be mounted remotely or within the canopy and are designed around local and national standards ensuring full compliance with regulations. CompAir can also offer remote monitoring capabilities. This provides useful data from the installation which can help to devise more efficient ways of working, including energy conservation, early fault diagnostics and shutdown planning.

14 1 AFTERMARKET Aftermarket The choice of equipment and the overall station design are two key elements which help to maximise availability of refuelling at a CNG station. The third critical element is preventative maintenance and full service support. With more than 00 CompAir service engineers in over 20 countries, CompAir prides itself on offering global expertise and experience with truly local backup and support. CompAir also has a strong distributor network with in-house CompAir trained service engineers. CompAir offers a comprehensive Aftermarket service designed to fully support the running of a CNG station, including: In-house service engineers Installation and commissioning Extended warranty Long term service contracts Refurbishment Servicing and supply of genuine spare parts Training Training CompAir have the ability to undertake CNG training all around the world including customer operator training, installation & commissioning training, and on-going service and maintenance training, either in-house or at the customer's premises.

15 GLOBAL PRESENCE 14 Global Expertise, Local Service COMPAIR OFFICE OR DISTRIBUTOR COMPAIR MANUFACTURING OR PACKAGING PLANT Reference list ACTION BUSES / AUSTRALIA ANUDIP GROUP / BANGLADESH BARLOWORLD MATERIALS HANDLING / UK BBA CONNEX GROEP / NETHERLANDS BEIJING HUAYOU UNITED GAS DEVELOPMENT CO. LTD / CHINA BRISBANE CITY COUNCIL / AUSTRALIA GASCO OIL (PAKISTAN) LTD / PAKISTAN CH JONES (KEYGAS) LTD / UK CHARLES DE GAULLE AIRPORT / FRANCE CONNEX / FRANCE FIAT / POLAND GAS AUTHORITY OF INDIA / INDIA GAZ DE FRANCE / FRANCE GOTEBORG ENERGI / SWEDEN HANJIN CITY GAS COMPANY LTD / KOREA H.S ENTERPRISE / BANGLADESH OIL & NATURAL GAS CORP / INDIA VEOLIA PROPRETE / FRANCE PALL-EX / UK PETROBAS / BRAZIL PETRONAS / MALAYSIA POLISH OIL & GAS COMPANY / POLAND QANTAS FREIGHT / AUSTRALIA SAFEWAY CNG / PAKISTAN STADTWERK WURZBURG / GERMANY Shanghai CompAir-Dalong HP Equipment Co. Ltd Established in Shanghai China in 2004, Shanghai CompAir-Dalong HP Equipment Co. Ltd (SCDL) is a joint venture between CompAir Group and Shanghai Electric Corporation Group. The company was established in China to manufacture a range of refuelling packages predominantly for Asian CNG markets, combining CompAir's global expertise and their advanced compressor technology with strong local knowledge, support and service capabilities. A separate brochure for SCDL is available on request or from our website

16 CompAir policy is one of continuous improvement and we therefore reserve the right to alter specifications and prices without prior notice. All products are sold subject to the Company s conditions of sale. Brochure re-order ref: E v2, 10/2006