CNG and CH2 Station Design Considerations - Low Carbon Fuels ...

MARATHONTECHNICALSERVICESCNG and CH2Station Design ConsiderationsSouthern California Clean Vehicle Technology ExpoOntario Convention CenterOntario, CaliforniaOctober 11, 2006Presented By:Rob Adams, P.Eng.Marathon Technical ServicesSponsored by:South Coast Air Quality Management District

MARATHONTECHNICALSERVICESIntroduction toMarathon Technical ServicesOverview of Services

MARATHONTECHNICALSERVICESFlexible Contract Approach•Design/Build•Detailed Design/Construction Support•Design/Build/Operate/Maintain fuel supply contract•On-going supportStation Design Services• Project Definition and Sizing• Electrical / Mechanical / Civil Design• Detailed Equipment / Installation spec’s• Engineering Estimate• Bid Period Assistance• Regulatory Approval Submissions• Contractor Submittal Review• Site Inspection / Supervision• Equipment Inspection and Testing• Noise Analysis

MARATHONTECHNICALSERVICESMarathon will provide concept level, or detailed design forfacility upgrades. These upgrades may include:•HVAC•Electrical•Structural•Gas DetectionFacility Modifications

MARATHONTECHNICALSERVICESAccident Investigation and ReconstructionMarathon's experience in incident investigationcontributes to the safety and integrity of our stationdesign and facility modifications.Deflagration in a indoor fuelingfacility. Marathon providedinvestigation and redesignservices for the facility.Rupture of a 200 psi vesselcausing the destruction ofthe CNG compressor.

MARATHONTECHNICALSERVICESTraining and Industry Resource•CNG Industry Best Practices—Suite of CD basedtraining modules funded by US DOE and GTI anddistributed free of charge through NREL.•We have trained staff from most of the CNG stationequipment manufacturers, CNG industry consultants(our competitors) and many CNG Station owners andoperators.•Authored or coauthored technical publications for theCNG Industry on behalf of gas industry groups.•Customized Standard Operating Procedures (SOPs).

MARATHONTECHNICALSERVICESCompressed Natural Gas (CNG)andCompressed HydrogenFueling Station Project Steps

MARATHONTECHNICALSERVICESSizing Steps:1.Define the fill shift (eg. One hour, overnight,or periodically throughout the day).2.Determine the total fuel dispensed per fillshift.3.Be careful not to under-estimate or overestimate time available and fuel dispensed—this could result in under-sizing (leading topoor fills or overtime) or over-sizing (leadingto station reliability issues and increasedpower costs).

MARATHONTECHNICALSERVICESSizing Steps:4.Provide fleet data to your consultant orturnkey contractor.5.Computerized station sizing tools are alsoavailable but some level of experience instation design is recommended before use.6.Evaluate station options:• Time Fill• Cascade Fast Fill• Buffer Fast Fill• L/CNG

Time-Fill Fueling Station SimulationNGUtilityMainGasDryer3100% 75% Full Full2100% 50% 75% FullTemperatureCompensation1100% 50% 75% Full

Time-Fill Stations-Small and LargeVehicle RefuelingAppliances (VRAs) areused in a wide varietyof applications both astime-fill (direct fill fromunit), or with a smallcascade storage toallow limited fast-filling.Courtesy FuelMakerCommercialapplications fuel 1-2vehicles over an 8hour period. Thismodel hasapproximately 2 scfmflow.

Cascade Fast-Fill Fueling Station SimulationStorage BypassNG UtilityMainGasDryerCompressorPriority FillSystem3-HighCascade2-MedStorage1-lowTemperatureCompensationCNGSequencing Valves3100% Full

Cascade Fast-Fill Fueling Station SimulationStorage BypassNG UtilityMainGasDryerCompressorPriority FillSystem3-HighCascade2-MedStorage1-lowTemperatureCompensationCNGSequencing Valves4 100% 70% 10% Full

Cascade Fast-Fill Station ComponentsElectric drive CNGcompressor packageSingle towernatural gasdryer withmanualregenerationTwo hose fuelingdispenser withinternal sequencing3 bank CNGstoragecascadeNatural gas utilityserviceCourtesy GreenField

Combination Time-Fill and Cascade

Buffered Fast-Fill Fueling Station SimulationBufferStorageNG UtilityMainGasDryerCompressorsTemperatureCompensation

Buffered Fast-Fill Fueling InstallationsLarge state-of-the-artBuffer Fast-Fill FuelingStation, AtlantaGeorgia.Courtesy ANGIFour 1000 scfmcompressors, 70,000 scfBuffer capacity, five fastfillhoses. Installationsized for 200 transit busfleet.

Simplified L/CNG SimulationLiquefied to Compressed Natural Gas (L/CNG) is CNG made from LNG. L/CNG isstill relatively new to the market. This technology does not require the natural gasservice to the site, the gas filtration and drying equipment and the gascompressor(s).Liquefied natural gas is stored on site in oneor more storage tanks (Cryogenic Thermos)with up to 10,000 US gallons per tank.LiquefiedNaturalGas (LNG)-259º F100 psigLNG is pumped up to 4000 or 5000 psig using 1 ormore high pressure Cryogenic PumpsLNG is converted to CNGby flowing it through a“vaporizer”. The vaporizeruses ambient heat tovaporize or boil the liquidinto gaseous form.Using current technologyit is not possible tomaintain odorant in LNG.Odorant is required bycode and must be injectedinto the gas after it hasvaporized.L/CNG can be dispensedthrough a conventionalTime-Fill, Cascade Fast-Fill, or Buffer Fast-Filldispensing system.

L/CNG Fueling InstallationsCourtesy NexGenLNGStorageTanksCourtesy Nexgen FuelingVaporizerConcrete LNGContainment WallCNG Dispensernot shown(behind bus)

MARATHONTECHNICALSERVICESProject Steps:1.Determine whether a consultant will be hiredor whether a design-build contractor will beselected (consultant still recommended).“Fuel Provider” contractors are anotheroption that relieves the owner ofmaintenance responsibility. This approachis most commonly used on LNG, L/CNG andH2 projects, but has also been used onTransit and other CNG stations. The fuelcost includes O&M (except power).

MARATHONTECHNICALSERVICESProject Steps:2.Sizing and selection of station type.3.Conceptual design/layout identify sitelimitations or considerations.4.Determination of utility requirements-newgas, power, phone and Internet services tothe site.

MARATHONTECHNICALSERVICESProject Steps:5.Preliminary visit to regulatory agencies—adjust design as required.6.Issue equipment and installationspecifications and drawing package—detailis equally important with design-buildapproach.

MARATHONTECHNICALSERVICESProject Steps:7.Station construction. (between 3 and 12months)8.Station commissioning and testing—Alt-fuelvehicles are required to test the station.(between 2 weeks and 3 months).9.Final regulatory approval.10.Operations begin—spare parts should be ininventory by this point. Expect a “shakeout” period of several weeks—longer withlarger stations.

MARATHONTECHNICALSERVICESCNG, LNG, L/CNG and H2 station projectsoften span more than a year from inceptionto final commissioning.Plan Early!!

MARATHONTECHNICALSERVICESTransit CustomersMETRO REGIONAL TRANSIT AUTHORITYGWINNETT COUNTY TRANSITM

MARATHONTECHNICALSERVICESOEM Customers

MARATHONTECHNICALSERVICESOther CustomersU.S. Department of EnergyCity ofSanta MonicaconEdison, inc.SYSTRACONSULTING

MARATHONTECHNICALSERVICESCNG StationDesignResearchBuildingUpgradeDesignAccidentInvestigationTrainingCNG Station SupportMarathon Technical Services(519) 699-9250radams@marathontech.caWWW.MARATHONTECH.CA