Setting Up A Natural Gas Fast Fill Station

Natural Gas Vehicles utilize natural gas drawn from onboard storage tanks. In order to have enough fuel available in the vehicle, the natural gas must be compressed and transferred into the storage tanks.
An NGV refueling station takes natural gas delivered by the local gas distribution company and increases the pressure to load into the onboard storage.

The basic quick fill station will take pipeline quality gas delivered at 5 psig and pump it up to 5,000 psig for ground storage. From gas company connection to the vehicle, the major components of the station are outlined below.

Inlet Gas Line (from your local utility)

Inlet Dryer – used to reduce the moisture content of the gas. Pipeline quality gas typically has a moisture content of 7#mmscf. This must be reduced in order to meet the Society of Automotive Engineers fuel spec J1616.

Inlet Filtration – used to filter out any dirt or pipe scale.

Natural Gas Compressor – This is really the heart of the system. An Ingersoll Rand compressor package includes the compressor, an electric motor, motor starter, cooler and controls. The compressor package will increase the inlet pressure from 5 psig up to 5,000 psig.

Priority/Sequence Panel – A valve panel that directs the gas flow to either high pressure storage or directly to the vehicle. This panel also insures temperature compensated fills.as well as directs gas flow to storage or to vehicle.

ASME Storage – typically ASME vessels rated to hold natural gas at 5,000 psi where it is held until a vehicle is connected to the station.

Gas Dispenser – dispenses gas into the vehicles and measures the amount transferred.

 

TYPICAL NATURAL GAS FAST-FILL STATION

 

Fast-Fill Dispenser:

FAST-FILL STATION DISPENSER IS LOCATED AWAY FROM THE COMPRESSOR PROVIDING ROOM FOR VEHICLE REFUELING.

 

Fast-Fill Station Requirements:

• Electrical disconnect within view of the equipment
• Two (2) 2” Conduits for 480V/3 Phase
• Two (2) 1” Conduits for 110V
• Two (2) 1” Conduits for methane detectors
• Two (2) 1” Conduits for spares
• Two (2) 5/8” OD Copper ground rods
• One (1) 1-1/2” Inlet gas line
• Two (2) 1” Conduits for dispenser
• Two (2) 40’ (based upon where refueling island is located) lengths of ½” OD X .065 wall, 316 stainless steel tubing
• One (1) 1” Conduit for 110V to dryer
• One (1) Conduit for ESD switch
• Two (2) 120 VAC 4PDT relays with sockets for ESD

In the United States, NFPA-52 is the ruling body on how NGV Refueling Stations are installed.