TORRENT GAS TRAINING

MODULE
Design, Installation, Testing, Commissioning,
Operation & Maintenance
of CNG Station
Contents
• CNG Station Sizing

• Equipment Specifications

• Installation & Commissioning of CNG stations

• Operation & Maintenance Philosophy

• Safety Aspects of CNG Vehicles

CNG Station Layout
• CNG stations are co-located with petrol pumps, Private and company owned lands.

• All CNG installations are follows basic layout plan approved by Chief Controller of
Explosives (CCOE), Nagpur or their respective local area offices.

• Safety distances for the CNG station layout is as per the guidelines laid down in Gas
Cylinder Rule 2016, OISD 179 & T4S of PNGRB are followed .
Inter distances between various
facilities in CNG station

Total capacity of gas storage Minimum distance from buildings

cascade units ( in liters) and boundaries (in meters)
Up to 4500 2.5

4500 to 10000 4

10000 to 100000 10
Typical Station sizing consideration
• CNG station sizing is based on the following:
1. Gas network pressure
2. Area of land
3. Mother station or online station or DBS
4. Vehicle population

• Normally Compressors are rated at 16 barg suction & 250 barg discharge pressure, further compressor
inlet rated depends on availability of pressure i.e. 30 to 45 barg at CGS station
• CNG station having 1200 scmh compressor is installed with 6 to 8 dispensing points (i.e. 3 to 4 dual
hose dispenser)
Typical Schematic of Gas Pipeline
Network System CNG CNG
Retail Retail
Outlet Outlet
GAIL City
Gate
19-38 bar 19 bar CNG
Station
Retail
Outlet

District
Regulating
Station

4 bar
Meter Service
Regulator 100 mbar Regulator
 Typical CNG Station
1.CNG mother station :
CNG facility connected to Natural gas pipeline & having a
compressor meant primarily to fill mobile cascades for daughter
booster stations. Such station also can fill stationary cascades for
CNG dispensing into vehicles.

2. CNG Online station :

CNG facility connected to Natural gas pipeline & having a
compressor meant primarily to fill stationary cascade for dispensing
CNG to vehicles. In case the online station has enough space to
accommodate mobile cascades filling, it can be used to act as
mother station.

3. CNG Daughter-booster station:

CNG facility not connected to natural gas pipeline & dispensing
CNG to the vehicles through mobile cascades.
Typical Mother station
TYPICAL CNG MOTHER STATION

250 BARG

250
BARG

16-19 BARG

GAS SUPPLY "CNG"

COMPRESSOR

LCV-MOUNTED-CASCADES

200 STORAGE
BARG CASCADE

CNG VEHICLE
Typical Online station
TYPICAL CNG ONLINE STATION

250 BARG

16-19
BARG

GAS SUPPLY "CNG"

COMPRESSOR

200 STORAGE
BARG CASCADE

CNG VEHICLE
Typical Daughter Booster station
250 BARG

250 BARG

LCV-MOUNTED-CASCADES "BOOSTER"
COMPRESSOR

200 STORAGE
BARG CASCADE

CNG VEHICLE
General Specifications of CNG
Compressors
• Compressor type : Reciprocating Piston type
• Codes & standards : API 618 / API 11P, 2nd edition (replaced with ISO 13631) / other relevant reputed
international standards
• Type of Cooling : Air or water cooled
• Inlet suction pressure : 10 to 18 barg (nominal value : 16 barg)
• Discharge Pressure : 250 barg
• Drive : Electric Motor driven / Engine driven (direct coupled or belt driven)
• Flow : 600 scmh, 1200 scmh, 1600 scmh & 2000 scmh etc.,
 Safety features in CNG compressor
• Design of compressors conforms to API 618/API 11P / Other relevant International Standards
• Construction of piping / tubing of compressor conforms to ASME B31.3
• All compressor are mounted inside a weather-proof (protection level equivalent to IP 44 as defined in
AS 1939) acoustic enclosure to give sound level of max 70 dBA at 1 mtr distance
• All electrical devices, control panel, instruments etc. suitable for hazardous area classification class I,
Div I, Group D as per NEC or Zone–I, Group IIA/IIB as per IS/IEC specifications or equivalent
specifications
 Safety features in CNG compressor
(Cont.,)
• Pressure transmitters / pressure switches provided on inlet, all inters stage and discharge lines for
automatic shut down of compressor in case of high / low pressure in respective lines

• Pressure Relief valves provided on suction inlet as well as outlet of all stages to prevent pressure built-
up above predetermined set point

• Temperature transmitters / switches provided on final discharge gas line to shut down the compressor
in the event of a high discharge temperature
Safety features in CNG compressor
(Cont.,)
• Temperature switches provided on lubricating oil line and cooling water line (in case of water cooled
compressor) to shut down the compressor in the event of a high temperature fault on respective lines
• Low lube oil pressure switch for automatic shut down of the compressor in case the lubricating oil
pressure drops below set point
• Gas detection system consisting of 2 nos. Infrared type LEL detectors provided inside the
compressor enclosure for automatic shut down of the compressor in the event of gas leakage.
• Flame detectors (2 nos. UV type) provided inside the compressor enclosure for automatic shut down
of the compressor in the event of detection of flash inside the compressor enclosure.
Safety features in CNG compressor
(Cont.,)
Other safety features
• Low oil level protection switch
• Cooling water flow switch
• Cooling water temperature switch
• Vibration level switch
• Drive belts used are of antistatic type and are fire resistant
• All the equipment’s and components used in the package are
fire retardant
Various makes of CNG compressors
• KPCL, India
• CP, India
• Savior, India
• Tulip, India
• SAFE spa, Italy
• Intermech, New Zealand
• Delta Compression, Argentina
• Sulzer, Pune , India
• Dresser Rand, Naroda, India
• Bharat Pumps & Compressors Ltd. Alahabad, India
• Dresser Wyne Pignone, Italy
• Endurance, China
Three stage reciprocating compressor with
intercoolers
Cooling water out
Cooling water in

Intercooler Intercooler

P1,T1

P2,T2 P2,T3 P3,T4 P3,T5 P4,T6

After cooler
1st stage 2nd stage 3rd stage
P4,T7
 Multi –stage compression
6
7 a
The amount of work saved due to
intercooling is shown by the shaded area
2-a-6-5-4-3
5
4
Pressure

3
2

8 1

Volume
Typical Layout of Tubing
Compressor S.S. Tubing

L M H

NRV
Stationary
Cascade

H
M
Dispenser
L
General Specifications of CNG Dispensers
• Type : 3 line electronic, microprocessor based automatic sequencing
• Codes and standards : NFPA – 52, NZS 5425 (latest edition), ANSI, Oil Industry Safety
Directorate (OISD) 179
• Metering device : Mass flow meter based on Coriolis principle
• Inlet pressure : Up to 250 barg
• Outlet (fill) pressure : 200 barg
• Flow rate : 15 kg/min for car & 75 kg/min for bus dispensers
• Batch Accuracy : + 0.5% for dispensed gas
 Safety features in CNG dispenser
• Design of dispenser conforms to NFPA-52, NZS 5425, Oil Industry Safety Directorate (OISD) 179 /
relevant international standards
• All the electrical and electronic components are mounted in flame/ explosion proof housing suitable for
hazardous area classification of Class I, Div 1, Group D as per NEC or Zone 1, Group IIA/IIB as per
IS/IEC specifications
• Dispensers are housed in weather-proof cabinet of robust construction and stainless steel (SS 304)
material with a tamper proof locking arrangement
• Dispensing units have overfill protection through electronically programmed microprocessor with 2
nos. of pressure limiting device per filling line
Safety features in CNG dispenser (Cont.,)
• Construction of piping / tubing of dispenser conforms to ANSI B31.3and is of SS 316 material
confirming to ASTM A269
• Pressure Relief valve provided on each filling line to prevent pressure built-up above
predetermined set point
• Dispenser refueling hose provided with return vent line hose for safe venting of gas.
• Dispensers are provided with easily accessible emergency shut off valve on each filling line
Safety features in CNG dispenser (Cont.,)
• Dispenser automatically shuts off CNG supply in case of
• Power Failure
• Loss of display
• Over fill

• Break away coupling provided on each filling hose

• Filling hoses used are electrically conductive to avoid any static charge
 Schematic of Dispenser
Electronic Circuit
220 V AC
Check Valve

Display

00002.02
Rs 00044.12

22.06
Actuator MFM sensor
With Dome load valve
Solenoid
coil
3-way valve

One feet hose

Probe
H M L
Various makes of CNG dispensers
• Parker, India
• Compac, India
• TGT, India
• SAFE spa, Italy
• Delta Compression, Argentina
• Fuelling Technologies Inc., Canada
• Kraus Global, Canada
 General Specifications of CNG
Cascades
• Total Water Capacity : 3000/ 4500 ltr
• No. of banks : 3 banks viz. Low, Medium & High
• Working Pressure : 250 barg at 15ºC
• Cylinders : Seamless chrome-moly alloy steel As per Gas Cylinder Rules 2004, and IS 7285 part II
and prior approval of Chief Controller of Explosives (CCOE), Government of India
• Provision of inbuilt canopy for protection from sun & rain
Various makes of CNG cascades
• Everest Kanto Cylinders Ltd, Mumbai
• RAMA cylinder, Gujarat
• Bharat Pumps & Compressors Ltd. Allahabad, India
• MKC, India
• LUXFUR cylinder
• ACE Cylinder
CNG cascades – 4500 WLC
 Safety features in CNG Cascade
• Construction, licensing & inspection, markings, fitment, handling, storage and all other
relevant aspects of cylinders and fittings are as per ‘The Gas Cylinder Rules’ and are
approved by Chief Controller of Explosives (CCOE),
• Cylinders are mounted on a robust frame structure which does not allow lateral /
rotating movement of cascade in any condition
• Cascade frame structure suitable to withstand impact of 4 G force from any direction
• All cylinders are subject to hydraulic stretch test at a minimum pressure of 422 bar or to
pressure as determined and approved by CCOE and as required under rules 39 to 42 of
Gas Cylinder Rules, 1981 (India)
 Safety features in CNG Cascade (Cont.,)
• Construction of piping / tubing of cascade conforms to ANSI B31.3and is of SS 316 material
confirming to ASTM A269
• The cylinder valves conforms to requirements of IS: 3224 or are as per approved design by
Chief Controller of Explosives (CCOE), Govt. of India.
• All cylinders are provided with safety relief device consisting of fusible burst disc assembly as
approved by Chief Controller of Explosives (CCOE)
• The burst disc discharge is manifolded to a common header for safe venting
• All cylinders are periodically examined & hydrotested every three years as per ‘Gas Cylinder
Rules’ 2016
 Safety features in CNG Station
• All electrical fittings including light in compressor as well as dispensing area are flame /
explosion proof suitable for hazardous area application
• Emergency shut down switch is provided near compressor, dispenser & sales room area to
immediately shut down the equipment as well as supply CNG in the event of any mishap /
undesirable event
• CNG compressor & storage area is isolated by providing chain link fencing / boundary walls
• Safety sign boards are displayed in English, Hindi & Local Language at CNG stations as per
guidelines laid in OISD – 179
• Fire fighting equipment’s are kept near CNG area as per guidelines laid in OISD - 179
 Installation & Commissioning
• Major installation activities for CNG station are as follows :
 Installation of Compressor, dispensers & cascade as per layout drawing approved by
Chief Controller of Explosives (CCOE), Nagpur
 Laying and hook up of suction gas line (incase of online & mother stations)
 Electrical installation
 Interconnecting high pressure tubing between compressor, cascade & dispensers
 Civil work such as boundary wall, fencing etc.
 Installation & Commissioning (Cont.,)
• Inspections & Statutory compliance :
 All CNG equipment are inspected prior to dispatch at the vendors works by independent Third
Party Inspection agencies such as Bureau Veritas, TUV & SGS
 All electrical installations are carried out by PWD licensed contractors
 After installation of CNG facilities station is audited prior to commissioning by Third Party
Inspection agencies such as Bureau Veritas, TUV & SGS
 Complete installation along with leak test on high pressure line are witnessed by Third Party
Inspection agencies such as Bureau Veritas, TUV & SGS
 After completion of installation work requisite operational licence is obtained from Chief
Controller of Explosives (CCOE), Nagpur
 Installation & Commissioning
(Cont.,)
• Inspection is carried out by local office of Petroleum & Explosives safety Organization and the
operational license is issued

• Commissioning activities are carried out as per safe operating procedures of TGPL & OEMs of
respective CNG equipment’s and then the commercial sale is started
 Functions of Operation Team
• Ensure smooth , consistent & safe operation of CNG station
• Monitoring daily CNG sales
• Attend day to day breakdowns / complaints at R.Os
• Monitoring compressor parameters logged by the operator to ensure the healthy conditions of all the
equipment’s to take corrective actions wherever necessary
• Carrying out monthly safety audits
• Ensure Safety & Technical audit by independent Third Party Inspection agencies approved by
PNGRB at set frequency, such as Bureau Veritas, TUV & SGS etc.,
 Functions of Operation Department
(Cont.,)
• Statutory compliances such as periodic test of cascade cylinders, various measuring instruments, gas
& flame detectors, mass flow meters etc.
• Effective implementation of complaint log system & tracking the same
• Maintenance / Renewal of all various statutory licenses such as Operational license from Chief
Controller of Explosives, Factory permits etc.
• Imparting training to compressor operators, dealers & dispensing staffs
• Organizing safety awareness programs at CNG stations
 Maintenance Philosophy
• 100 % adherence to Preventive Maintenance schedule of all equipment ( as per OEM’s schedule)
• Periodic calibration of measuring & protection devices such as SRV’s, Gas & flame detectors,
Pressure gauges & transmitters, temperature gauges & transmitters, Mass Flow Meters etc.
• Ensure good & safe engineering practices while carrying out maintenance
• Implement permit system for any work within CNG area (Hot permits, Working at height, PTW for
maintenance)
Functions of Maintenance Team
• Ensure 100% adherence to Preventive Maintenance schedule
• Ensure more than 98% availability of CNG stations
• Spare parts & inventory management
• Vendor development
• Health monitoring of CNG stations
• Statutory compliance
Typical Maintenance Activities for
Compressor
After 1000 running hours
• Checking compressor valves, leakages in air, water, gas circuit and take corrective action if
required.
• Cleaning of gas & oil filters and replace them if required.
• Checking the functioning of priority panel, switches & actuator valves.
• Cleaning of radiator tubes, fins with air and water jet. Also check for coolant level in radiator and
top up if required.
• Checking the condition of coupling of motor with compressor.
Typical Maintenance Activities for
Compressor
After 2000 running hours
• All the activities carried out in 1000 hours maintenance
• Checking of valve plates / springs and replace if required.
• Checking the condition of piston and piston rings and replace if required.
After 4000 running hours
• All the activities carried out in 2000 hours maintenance
• Changing of the lubrication oil.
• Changing dynamic seals and O rings of piston and rod.
• Checking the pneumatic valves of the compressor.
Typical Maintenance Activities for
Compressor
For the Compressor (8000 hrs.)
• All the activities carried out in 4000 hours maintenance
• Replacement of piston rings, cylinder liners & dynamic seals.
• Checking seizes of Piston, piston rod & Cylinder
• Checking of Crank and main bearing.
Thank You