HIGH PRESSURE CNG REFUELING SOLUTIONS - Atlas Copco
HIGH PRESSURE CNGREFUELING SOLUTIONSIntermech BBR/FBR/VIP CNG Compressors (75-600 hp)
Atlas Copco:Committed to your sustainable productivity4Atlas Copco4Atlas Copco is an industrial group with world-leadingpositions in compressors, expanders and air treatmentsystems, construction and mining equipment, power toolsand assembly systems. The company founded in 1873is based in Stockholm, Sweden, and has a global reachspanning more than 170 countries.All around the world, companies rely on Atlas Copco’sexpertise and innovations to contribute to their businessgrowth. Atlas Copco helps them cut costs and boostproductivity while taking care of the environment.With a comprehensive product offering, Atlas Copco isa trusted partner in the Compressed Natural Gas (CNG)industry. Atlas Copco invests heavily in R & D to ensurethat the latest technology is available to their customers.4Benefits of working with Atlas CopcoGas station owners require their CNG compressors to bereliable and energy efficient with no compromise on safety.Gas stations rarely have stand-by compressors - thereforereliability is an extremely important criteria when investingin the right compressor. The Atlas Copco CNG machinesare built to run trouble free with long service intervalsand are ideal for such a demanding application.Gas station owners look for the lowest operating costs.Atlas Copco range of INTERMECH BBR /FBR /VIPmachines ensure one of the lowest operating costs inthe market which adds to the bottom line of the gasstation owner.Gas stations prefer working with Atlas Copco CNGproducts. These machines produce dense cool gasMajor innovation18951993Crepelle introducesthe first horizontalpiston compressor.1960Crepelle introduces thefirst teflon ring oil freepiston compressors.1921Greenfield (earlierknown as SulzerBurckhardt) developsa methane compressorfor filling vehicles.Intermech launches first BBRhorizontal balanced opposedCNG compressor with directcoupled pressurized crank case.19801930Crepelle introducesthe first process gaspiston compressor.Intermech launches the firstdedicated CNG compressorwith W configuration.
ensuring safe filling of all storage cylindersand more standard cubic meters are filled intoeach vehicle or trailer. Reliabilty, cost efficiencyand good performace makes Atlas Copco’s CNGcompressors preferred by gas station owners.The station owners look upon the compressor vendorto assist them with reliable aftermarket support.Atlas Copco with its qualified team of aftermarket specialistand presence in over 170 countries is well equipped tomeet such demands.1994Intermech launches the firstmother-daughter station inNorth-Western China.Greenfield launches the “DM”CNG compressor range, with“oil-less ” technology.2005Atlas Copco acquiresIntermech with its rangeof CNG compressorand accessories.Atlas Copco launches thevariable inlet pressuredaughter station compressorwith VSD drive to be oneof the best in class.1997Atlas Copco acquiresCrepelle based inLille, France.20092007Atlas Copco acquires Greenfieldand its complete CNG business.Atlas Copco launches the FBR gasengine driven compressor andbroadens its CNG market further.2012Atlas Copco expands its CNGproduction lines in Houston(USA), Lille (France), Wuxi(China) and Pune (India).
Atlas Copco total CNG solution4 Atlas Copco INTERMECH BBR/FBR/VIP stations are appreciated for their quality, safe operation, smooth running andcompact design.Online Station - StandardSupplyLineFilterDryerOnline Compressor FBR or BBRFill / Priority Panel*Mother Station - To truckSupplyLineFill / Priority PanelFilterDryerMother Station FBR CompressorsForecourt*Cascades*Daughter Station - From truckForecourtCasCadesFill / Priority PanelTo Industrial ApplicationsDaughter Station VIP CompressorPressure Reducing Station
CascadesForecourtTrailer StorageTrailer StorageFill Panel2 Hoses Max 5,000psiTrailer StorageTrailer Decant Panel* Component not required for dedicated trailer filling station
The three pillars of productivity41.High ReliabilityHigh ReliabilityHigh ReliabilityAtlas Copco CNG compressors are highly dependable and keep onperforming with minimal cost of ownership.Low maintenance due to direct drive44Avoids lateral loads on crankshaft andbearingsBelts not required to be replaced every sixmonthsAir cooled machines for trouble free running44Air cooled machines avoid stoppages due to scaling, pump andcooling tower failuresASME designed air cooled heat exchangers with straight seamlessexpanded L-finned tubes for life long dutySoft starter* enhances component life4Reduces electrical shock loads and resultsin longer lifeMaximum up-time due to 100% matched components444Integrated inter-stage separators extract oil and aerosols from the gasstream and provide pulsation dampening after each stage thereforeextending valve lifeGenerous sizing of downstream coalescing filters result in longchange intervalsUse of heavy duty roller bearings and fullflow pressurized lubricationsystem for the bearings* Applicable to specific models, refer specific technical quotes for details
Mini lube design gives longer life4Metered drop lubrication of cylinders through separatelubricator divider system reduce wear on rings4Restricted piston speeds result in longer ring and valve life4Synthetic rings result in low friction and reduced wearReduced maintenance due to low temperature44Low discharge temperatures by proper staging andlarge oversized efficient intercoolers, result in longervalves and piston life.Separate oil cooler extends period of oil changeMinimum vibrations reduce maintenance44Horizontal balanced opposed design and 3 dimensionalbalancing of components result in low vibrationsConcrete filled H-frame with integrated blowdown vesseland 3 point vibration pads further reduce the vibration ofthe packageReliability through material design444Use of latest technological advancement in material selection,valve selection and surface coating technologyHigh quality oil flooded mechanical sealSuperior material of the crankshaft
The three pillars of productivity42.Smart EnergySmart EnergySmart EnergyWith energy consumption costs typically accounting for80% of the total cost of ownership, the Atlas Copco rangeof INTERMECH CNG compressors are unmatched in theirability to provide guaranteed energy efficiency.Zero leakage through pressurized crankcase444Pressurized crankcase up to 25 bar(e) results in zerogas loss to atmosphereGas savings of up to 3% over unsealed compressorsat first start up. After time the wear causes theunsealed compressors to leak more, resulting insaving up to 6% with a sealed crankcase.Payback of the complete compressor within fewmonths just on gas savingUnloaded soft startingPart load power consumption is reduced by acombination of integrated blowdown vessel, soft starterand smart PLC programing / controls. This allows thecompressor to be programmed to load / unload,start / stop as per consumption levels.
Optimized Package design44Oversized heat exchangers have lowapproach temperatures and efficientintercooling, reducing power consumptionGenerously sized internal piping and vesselshave the lowest pressure drop resulting inlower power consumptionDirect drive44Up to 1800 rpm compressor running speedfor direct coupling of compressor to theprime mover, gas or electricNo belt transmission losses results insaving up to 5-7% of total energy costsEfficiency through design444Optimized number of stages ensurelow power consumptionBalanced opposed design and high degree of balancingof components, forces and dynamic loads allow closetolerances ensuring high volumetric efficiencyWear and tear is reduced due to smooth running andminimal vibrations leading to lower power losses
The three pillars of productivity43.SafetySafetySafetyWith many years of experience in CNG compressors andan enviable track record of safe operation extending overmillions of compressor running hours, safety is an integralpart of all our CNG compressors.Safety due to design44444The design of Atlas Copco CNG machines refersto international codes like TEMA, API and ASMEassuring safety.Control system are designed to monitor criticalcontrol points to guarantee safe operationMachines are designed for zoned area usingexplosion proof motors and suitable instrumentsCSA / NFPA 37 approved gas engineCSA insulated and sealed electronic digitalignitionSafety due to modern manufacturing44All components are built as per the latest industry standards usingthe state of the art for machining , welding and assembly. Modernwelding techniques with ASME qualified welders are used toconstruct the rugged designsOptional independent third party design verification of all pressurevessels, welding procedures and hydrostatic pressure tests
Safety due to worldclass sub vendors4Our philosophy of “Safety First” ensures that we qualify ourvendors based on their safety track record . Our critical keycomponents are sourced from world renowned companieswho have built a reputation of safety and reliability in the oiland gas marketSafety due to quality4Atlas Copco’s philosophy is to provide customerswith products that have been designed,manufactured and serviced to internationallyrecognized ISO 9001 quality assurance standards.This ensures that there is full documentation andtraceability of all materials and componentsSafety due to Testing4Each compressor is fully performance and safetytested with natural gas at its designed capacity at astate-of-the-art test facility with optional 3rd partycertification.Safe installation44Integrated design including pre-piped pulsation dampeners cumseparators, blowdown vessels, suction and discharge filters andnon return valve ensure that the installations are designed to promote safety featuresAtlas Copco’s experienced technical and field staff ensure safetyguidelines are explained
Atlas Copco range of compressorsINTERMECH BBR & FBR compressors with electric motor or gas engine4Package scope:4Inlet filter to compressor block4Pressurized crankcase up to 25 bar(e)4Electric motor/gas engine drive4Flexible direct coupling with coupling guard4444Air cooled intercooler/aftercooler and air cooledoil coolerPiping / stainless steel tubingIntegrated moisture separator / pulsationdampenerDuplex final filtration using coalescing filters toremove aerosols to less than 5 ppm4Integrated blowdown vessel4Lubricating system including gear pump, oil filter4Necessary instrumentation as per areaclassificationStandard features:Optional features:4Standalone PLC based control panel4Acoustic canopy suitable for 75 dBA4Soft starter above 110kW4Weatherproof canopy4Star delta starter 110kW and below43rd party certification4Gas detectorFlame detectorCompressor service characteristics:4LubricationTop up daily4Bleed and block valves for instrumentsValves6000 h4Flameproof lightingOver haul15000 h4Remote monitoringMain bearings35000 h4VSD soft starter4Chain hoist system
Advanced solutions with custom design4Customize standard products to customer requirementsWe customize our machines to offer tailormade solutions for realtime country conditions.Our solutions include:4Weatherproof acoustic enclosure for outdoor duty4Operation in sub-zero temperatures4Peak performance in very high ambient and dusty environments4Corrosion resistance for windy, coastal and offshore applicationsOne such customization is the MobileRefueling Unit ( MRU)Sometimes a mobile solution is required for remotelocation wherein the complete gas station is to bemounted on a movable trailerThis may be a temporary station used for checkingthe feasibility of the site or as a solution to be usedtill the time the permanent daughter station is setup.The Atlas Copco Mobile Refuelling Unit or MRUis a self-contained, skid-mounted unit for thecompression, cooling, storage, and dispensingof CNG. Mounted on a semi-trailer truck, it isquickly transportable and can be used as a mother,daughter or conventional station. Housed in itsacoustic canopy the MRU creates minimal sounddisturbance.It includes4On board CNG dispenser4Priority control system4Flexible hose for connection to CNG trailer orgas mains4Pressure reduction system for trailer operation4Metering and regulating system4On board storage cascadeThe MRU is a compact design and light weight. It iseasy to install and operate.
Variable inlet pressure (VIP) compressor4The Atlas Copco range of INTERMECH VIP modelsare 2-stage compressor packages especiallydesigned for daughter station service. They ensureefficient and quick unloading of trailers.Match trailer pressure to avoid costly regulationand re-compression:a pressure reducing valve or a regulator to bringdown the trailer pressure to 30-40 bar(e) and thenrecompress the same to 250 bar(e). The INTERMECHVIP uses a combination of innovative valve switchingand a variable speed drive to accept the variable inletpressure.The VIP package utilizes the pressure of the trailergas to reduce daughter station power requirements.Conventional daughter station compressors use4Why choose an efficient VSD daughter station?Variable inlet pressure44No pressure reduction and usepressure of trailerLowest energy costInverter VSD drive4Runs at different speeds depending uponsuction pressure4Maximum capacity specially at lower pressure4Less time for unloadingLargest operation band4Can work to minimum 15 bar(e) trailer suction pressure48 % more gas unloaded as compared to others4Less gas returned in each trip4Less tranport cost and quicker turnaround
500001030507090100130150170190Trailer pressure in bar(e)Average flow rate: 1590 Sm 3 /h* considering reference conditions and correct installation as per Atlas Copco guidelinesPower (kW)Flow rate (Sm 3 /h)Integrated oil tank4Cylinder lubrication from gravity fed integrated oil tank4Simplifies daily maintenance (no separate reservoir)Footprint4Extremely compact* Typical average flow between 190 - 15 bar(e) suction pressure actual performance depends upon pressure range,trailer volume, installation, gas properties and ambient conditions.Flow rate (Sm 3 /h)Motor power (kW)Representative INTERMECH VIP 2715 D Performance Chart
CNG accessories4CNG accessoriesThe Atlas Copco CNG accessories are a result of over 30 years of design philosophy crafted to deliver equipment that is highlyfunctional and robust, with full flow and minimal restricting points. They are working in numerous installations giving trouble freeservice to gas station owners, day after day.Priority fill panelIn case of fluctuating demand especially for publicgas stations, a 3 bank system helps to decantmore gas than a single bank system. It also helpsin reducing NGV fill times and reduces potentialservice problems of the compressor.Priority panels allow compressors to top up vehicles before directing the to the gas storage tank.Atlas Copco wall mounted priority fill panels use4Generously sized connections and piping from reputed brand4Mechanical prioritisation Have special springs loaded to achieve excellentmemory and consistent efficient sequencing Have full bore for high flow Are hand adjustable Are designed to prevent lower than set pressure inthe storage vesselElectronic prioritisation High flow rate design is achieved by use of 1/2” air actuated normallyclosed ball valves - in the event of air failure valves will be shut off byspring.
4Atlas Copco non return valves Proven for non-jamming technology Incorporates cleanable SS mesh filters4Very large bore emergency air actuated ball valvesto isolate forecourt dispensers from high pressuregas flow sourcesModelPrioritizationNumberof linesCapacityup to Sm3/hDimensionsFPA 17 Amechanical425000.3 x 0.6 x 1.1FPA 19 Amechanical325000.3 x 0.6 x 1.1FPA 23 Aelectronic350000.26 x 0.85 x 1.15FPA 31 Aelectronic4100000.4 x 1.45 x 1.45
CNG accessories4Gas flow systemsAtlas Copco has a large range of gas flow systems which are designed for:Energy efficiency:Engineered solutions to provide the highest flow rateby incorporating efficient low pressure drop by usingvery large bore fittings, tubing and hoses.Reliability:444Zinc plated fittings and stainless steel tubing fromworldclass manufacturersStainless steel frame or weather-proof stainlesssteel IP 23 cabinet (optional) to ensure long lifeInstrumentation from world-class manufacturersSafety:4Break-away coupling to ensure safe operation4Flame proof emergency push buttonSome examples4Trailer decant postDMA-TD2Twin hose trailer decanting 70 kg/min fitted with nozzledesigned to ISO 7241-1AS4Trailer fill panel DIN-100 M1WSingle hose metered cabinet dispenser suitable for100 kg/min
4CascadeAtlas Copco 3 - bank buffer storage are fully corrosionresistant and designed to the most stringent internationalstandards and regulations. These form an integral part ofthe total station solution.Benefits:Standards and ApprovalsAs per international standard444430 mm air gap between all cylinders.4Features burst disks on all valves to relieve gaspressure slowly in the event of an emergencyDOT – 3AA standard cylinders usedCompliant with NZS5425 which requires accessto all valves at less than 1.5m of heightFeature at least 3/8 inch (9.525 mm) SS Pigtailconnection for thermal and shipping movementallowanceModelLow bankMedium and high bankDimensionCAS 2054 A/B20 x 50 WL12 x 50 WL 8 x 50 WL1.94 x 1.64 x 1.2CAS 3054 A/B30 x 50 WL18 x 50 WL 12 x 50 WL1.94 x 1.64 x 1.5CAS 4054 A/B40 x 50 WL24 x 50 WL 16 x 50 WL1.94 x 1.64 x 1.7
CNG accessories4Pressure reducing system (PRS)Atlas Copco PRS reduce gas pressure from as high as 259 bar(e) to an exact output pressure (50 – 1 bar(e)) withouthydrate (icing) formation. They drain trailer to extremely low pressure. The CNG is heated before regulation by using hot wateravailable from the customer. We get an accurate output pressure from the PRS.PRS Principle components – features and benefits1211TEMA design water-in-tube shell and tube heatexchangers25Atlas Copco full bore spring or dome loadedregulator valves for regulating pressure in the firststage13 Accurate high flow final Regulator4Atlas Copco non return valves proven fornon-jamming technology5 Pressure gauges and relief valves on bothstages and discharge6 Galvanized frame and feet, pre-drilled for concreteanchoring to minimize corrosion
PRS :4Includes electrical heater (loose supply – suitable for safearea) with inbuilt water pump and temperature controller4The on board PLC system monitors flow , pressureand temperature and controls actuated valves forautomated control of the PRS344Inlet filter to remove particles and protect equipmentAdvantages:4In the event of water temperature drop the PRS automaticallyshuts down, preventing damage to tubes464When trailer pressure reaches critical level the first stageof regulation and heating is cut out to maximize systemefficiency. This helps to maintain flow rate down to verylow trailer pressureCompletely compatible with Atlas Copco trailer decant panel,the PRS provides an option of trailer pressure monitoringand seamless transition from empty to full trailersPerformance:ModelCapacity PRS 010Upto 1000 Sm3/hPRS 060 Upto 3000 Sm3/h
Our parts and service offering44Global presence – local serviceAt Atlas Copco, our responsibility does notstop when the product is delivered. Guaranteedserviceability ensures optimum availability andreliability of your CNG systems with the lowestpossible operating costs.Checks by Atlas Copco expert technicians followingfactory standards minimize the risk of breakdowns andproduction loss. Through an audit of your productionprocess, we can optimize the performance of yourequipment. We do that with a keen eye on maximumavailability at lowest cost.We deliver this complete service guarantee throughour extensive service network established in over 170countries of the world through our own companies orour partners4The value of Atlas Copco support plans:4Most cost-effecti
4Major innovation Atlas Copco is an industrial group with world-leading positions in compressors, expanders and air treatment systems, construction and mining equipment, power tools and assembly systems. The company founded in 1873 is based in Stockholm, Sweden, and has a global reach
For example; we see for a manufacture rated 23.5 gge CNG cylinder having refills in range of 17 - 20 gge's. CNG Cylinder Pressure - 3,600 psi at 70ºF CNG Cylinder Inspection Requirements - The CNG Cylinder must be inspected every 3 years or 36,000 miles, whichever occurs first, by a Certified CNG Cylinder and Fuel System Inspector (CNG-FSI).
In-Use Vehicle (CNG /Bio-CNG/LNG Dual Fuel Engine) For Replacement of In-Use Diesel Engine by New CNG/Bio-CNG/LNG Engine . vehicle and CNG / Bio-CNG/LNG engine as per Table 2 and 4 of AIS-007. CMV
Questar Gas Company: 7 CNG public stations, 12 CNG upgrades & 115 CNG vehicles Robinson Waste: 3 CNG refuse haulers Salt Lake City: 57 CNG & hybrid vehicles Semi-Service Inc : 1 CNG public station & 7 CNG vehicles St. George Express : 5 CNG airport shuttle vans
For example; we see for a manufacture rated 23.5 gge CNG cylinder having refills in range of 17 - 20 gge's. CNG Cylinder Pressure - 3,600 psi at 70ºF CNG Cylinder Inspection Requirements - The CNG Cylinder must be inspected every 3 years or 36,000 miles, whichever occurs first, by a Certified CNG Cylinder and Fuel System Inspector (CNG-FSI).
2012 Civic CNG Owner’s Manual Fuel Quality and Honda Refueling In order to insure that your Civic Natural Gas vehicle receives CNG fuel with quality equal to or above the NFPA-52 and SAE J1616 fuel standards, Honda only recommends that your vehicle be refueled at public commercial-grade CNG refueling station.
Marine CNG Transportation Transportation cost is the most important factor in the CNG chain. The cost of CNG marine transport is directly proportional to the volume of gas and distance between the gas source and the consumers. Since the early 1960’s the marine transport of CNG
7. Annexure VI Installation certificate for converted CNG / BIO-CNG vehicle 17/96 8. Annexure VII Checklist for third party checking or inspection of built-up CNG / BIO-CNG buses (New and In-use) and LNG buses (New) before registration 19/96 9. Annexure VIII Checklist for preventive maintenance of in-use CNG
CNG cylinder (1) is installed in the luggage compartment below luggage shelf (2). Luggage shelf (2) above CNG cylinder may be used for keeping lightweight lug-gage. CNG CYLINDER WARNING LABEL 72RMC004 You may find this label on the CNG cylin-der. MANUAL SHUT-OFF VALVE 72RMC001 Manual shut-off valve (1) is located on the left hand side of the .
