CNG Compression and Refueling Solutions

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CNG Compression and CNG Refueling

Swagelok fluid systems support clean energy technologies with reliable components for natural gas compression and refueling. Swagelok can help you achieve the compressed natural gas (CNG) refueling infrastructure performance you need across stations of any size by delivering appropriately rated fittings, valves, and other components, while also providing a variety of supporting engineering services.

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High-Pressure CNG Compression

Compressing natural gas reduces its volume, making storage and transportation more efficient and cost-effective. Essential components like fittings, valves, gauges, and hoses play a crucial role in compressing the gas, controlling its flow, and monitoring pressure to ensure safety and proper operation of your refueling station.

If the gas flow isn't controlled, it may cause uneven distribution of gas, leading to inefficient refueling and potential safety hazards. It can also result in over-pressurization of the system, which can damage equipment and increase the risk of leaks or explosions.

Similarly, if the pressure isn't monitored, the system may operate at unsafe pressure levels, which can compromise the integrity of the storage tanks and other components. This can lead to equipment failure, gas leaks, and even serious accidents. Regular monitoring ensures that the pressure remains within safe limits, maintaining the overall safety and efficiency of the refueling station.

Our products for CNG compression and refueling provide:

• Leak-tight performance: This is essential for reliable containment, keeping station users safe and protecting the environment from fugitive emissions. Swagelok products are designed to ensure leak-tight execution, providing peace of mind and maintaining safety standards.
• High-pressure performance: Critical for any fluid system in the CNG distribution process because natural gas is compressed to achieve maximum energy density. Swagelok's high-pressure components are engineered to withstand the demands of CNG applications, promoting efficient and safe operation.
• Preassembled system solutions: Swagelok’s pretested and proven designs simplify installation and maintenance processes, allowing for quicker development of natural gas infrastructure. This acceleration not only reduces downtime but also ensures that the infrastructure is reliable and efficient from the start.

Equipping CNG Fueling Stations

We provide a full portfolio of products and services to support CNG refueling station system requirements for natural gas distribution.

Mother and Daughter Stations:

These stations are designed to transfer large quantities of compressed gas into mobile daughter units. Typically situated near a gas pipeline, they feature large compressors, priority panels, cascade systems, and dual-fill dispensers.

Challenges Include:

• Capacity and supply: It's essential for the mother station to have adequate capacity to meet the station load and fill mobile cascades. Insufficient capacity can result in longer filling times, extended waiting periods, and dry spells at the daughter station.
• Continuous supply: Ensuring a steady supply of gas to the daughter station via mobile cascades can be difficult due to factors such as long distances between stations, poor road conditions, accidents, route closures, traffic jams, and vehicle maintenance issues.
• Mobile cascade utilization: Efficient use of mobile cascades requires constant monitoring to prevent unnecessary stoppages and delays.
• Safety: Safe operation of mobile cascades involves adhering to standards, detecting leaks, having emergency shut-down systems, over-pressure relief valves, and proper personnel training.

Cascade Fill Stations:

These stations primarily fill from storage tanks and are typically used for retail applications or vehicles that need refueling at different times.

Time Fill, Slow Fill, or Fleet Filling Stations:

These stations are generally used for fleets of vehicles that return to central locations for extended periods, such as refuse trucks, school buses, and similar fleets.

Combination Fill Stations:

These stations combine elements of cascade fast-fill, buffer fast-fill, and time-fill configurations.

Bulk Loading and Off-Loading or Decanting:

Bulk loading involves transferring CNG from one container to another using larger diameters, up to 1 in. on tube trailers and 2 to 4 in. in decanting systems, where pipes are more common.

Challenges Include:

• High-pressure storage: Similar to fast-fill stations, natural gas is generally delivered to the site via pipeline and compressed on demand. This requires high-pressure storage systems, which are expensive and need to be carefully managed for safety and efficiency.
• Redundancy and reliability: Cascade fill stations often need multiple compressors to ensure continuous operation. This redundancy is crucial because if one compressor fails, the station can still operate, but it increases infrastructure complexity and cost.
• Temperature management: Rapid compression of natural gas can cause significant temperature changes, affecting gas density and refueling efficiency. Proper temperature management systems are essential to maintain performance.
• Maintenance and safety: Regular maintenance is critical to ensure the safety and reliability of cascade fill stations. This includes checking for leaks, ensuring compliance with safety standards, and maintaining high-pressure components.

Swagelok supports CNG compression and refueling with:

• Tube Fittings
• Natural Gas Hoses
• All-Metal Flexible Hose
• Ball Valves
• Relief Valves
• Bleed Valves
• Manifolds
• Instrument Manifold Valves
• Regulators
• Measurement Devices
• Tubing

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