CNG REFUELLING SOLUTIONS

INTELLIGENT AIR AND GAS TECHNOLOGY

01

SOLUTIONS

Intelligent CNG Solutions

With over 1000 CNG compressors supplied worldwide CompAir has been involved with the manufacture and installation of compressed natural gas refuelling systems since the early 1980s. During this time CompAir has supplied to over 25 countries with stations in the UK, Germany, France, Netherlands, USA, Brazil, Malaysia, Korea, China and Bangladesh, and are the market leaders in Poland, Australia and Pakistan.
CompAir meet the needs of a diverse range of customers through a series of modular, ready-to-run packages based around the Gazpack range of air and water cooled reciprocating compressors. The Gazpack series is designed to cover the full range of station types from pilot projects and small forklift fleets, through to high capacity public stations and large bus refuelling depots. Designed for flexibility and ease of installation, the Gazpack series is available in a wide range of packaging options. With advanced compressor design, extensive turnkey project experience and a truly local service capability, CompAir offers a Total Solution approach to CNG refuelling.

COMPAIR IS A WORLD LEADER IN THE DEVELOPMENT OF MODULAR SYSTEMS FOR COMPRESSED NATURAL GAS REFUELLING

WHETHER YOUR MOTIVATION IS ENVIRONMENTAL, FINANCIAL OR POLITICAL, COMPAIR HAS THE SOLUTION TO MEET YOUR NEEDS

SOLUTIONS

02

PROVIDING RELIABLE COMPRESSION SOLUTIONS SINCE 1898

The Gazpack range of CNG compressors is manufactured primarily at the state-of-the-art CompAir facility in Ipswich, England. The company moved from the original Reavell factory, established in 1898, to Reavell House in 2005 and enjoys enhanced manufacturing, test and paint facilities, as well as environmentally friendly water and oil recycling systems. Shanghai CompAir-Dalong HP Equipment Co. Ltd, a Joint Venture established in China in 2004, also designs and manufactures European quality CNG stations for the Chinese and Asian markets. As a manufacturer of CNG systems, CompAir retains greater control over quality and technological improvements in the compressor package, and a dedicated team of highly experienced project and design engineers is able to customise the Gazpack range to meet specific customer needs. Combined with specialist partners who are carefully selected to provide quality ancillary equipment such as dispensers and dryers, CompAir is able to provide a complete and reliable solution to meet the customer's refuelling needs.

CompAir is registered to ISO 9001-2000 Quality Management System by Lloyds Register Quality Assurance and conforms to the requirements of the European Pressure Equipment Directive (Module H) where appropriate. Witness testing and certification by most major accreditation bodies, such as Lloyds Register and TUV, can be met on request.

COMPAIR MANUFACTURES QUALITY CNG COMPRESSION PACKAGES UNDER THE ISO 9001-2000 QUALITY MANAGEMENT SYSTEM

03

SOLUTIONS

Turnkey Solutions
With over 25 years experience in the CNG industry CompAir has extensive experience providing project management assistance for turnkey projects.
CompAir offers the expertise to develop a complete refuelling station, covering: Project feasibility Site suitability Planning and approvals process Station and equipment design Utility procurement Equipment manufacture Site preparation Installation Commissioning Training

PROVIDING TURNKEY PROJECT MANAGEMENT FOR OVER 25 YEARS

Station Design
Station design is a critical part of any refuelling station project. The CompAir team of experienced sales managers and engineers can advise on all aspects of station design, taking into account the station type, fleet type and purpose, fill volume, site limitations, budget and other issues.

Fast Fill
Fast Fill stations primarily utilise gas drawn from a storage bank previously filled by the compressor, rather than direct from the compressor. The speed of fill is comparable to petrol or diesel and is typically found on public forecourts. This method is always used where the exact volume of gas in each vehicle must be quantified.

STATION DESIGN

04

Time Fill
With time fill posts the vehicle is refuelled directly from the compressor without the need for storage cylinders. Refuelling is therefore slower and more suited for vehicles left overnight at a depot, such as buses. With time fill posts the quantity of fuel dispensed into each vehicle is not easily monitored and therefore time fill is unsuitable for public refuelling stations.

Mother & Daughter

The mother-daughter concept is a 'virtual pipeline' where natural gas is drawn and compressed from the pipeline at the Mother site and transported to the Daughter site by truck and trailer. This is usually used to service sites that are not located near a natural gas pipeline. Once at the daughter station vehicles can be filled directly from the trailer using a CNG dispenser. The mobile cylinders are filled to above 200 bar at the mother station but due to pressure drops during decanting, it is essential to have a compressor on site to ensure pressure in the delivery line remains above 200 bar. When the pressure in the trailer cylinders finally drops below 20 bar, the trailer is returned to the mother station for refilling. A daughter station will usually have several trucks and trailers working on a shuttle system.

THE MOTHER-DAUGHTER CONCEPT IS IDEAL FOR SITES NOT ON A PIPELINE

05

MODULAR SOLUTIONS

Modular Solutions
THE GAZPACK RANGE IS A MODULAR READY-TO-RUN SYSTEM AVAILABLE IN A VARIETY OF CONFIGURATIONS, CUSTOM-BUILT TO MEET CUSTOMER SPECIFICATION.
EXAMPLE A EXAMPLE B

Skid mounted compressor and inlet train

Skid mounted compressor and inlet train with cooling system

EXAMPLE G

EXAMPLE F

Fast Fill Station - full turnkey project

Time Fill Station - full turnkey project

COMPAIR IS ABLE TO SUPPLY GAZPACK MODULES & ANCILLARIES TO MEET MOST CUSTOMER REQUIREMENTS

MODULAR SOLUTIONS

10

EXAMPLE C

EXAMPLE D

Bedplate mounted compressor and inlet train with cooling system, filtration and gas recovery

Bedplate mounted compressor and inlet train with cooling system, filtration and gas recovery system contained within a weatherproof acoustic enclosure

EXAMPLE E

All Gazpack modular packages are available with stand alone ancillaries, including control panel, cascade storage and dispensers.

SUPPLY ONLY

SUPPLY & INSTALLATION

FULL PROJECT MANAGEMENT

07

PRODUCTS

Advanced Compressor Design

Compact modular design provides a small footprint unit with maximum flexibility Well balanced compressor design, plus the use of anti-vibration mounts and flexible connections removes the need for special foundations and reduces vibration Individual, compression stage separation using CompAir designed high efficiency separators reduces moisture carryover between stages thereby increasing component life Gas recovery system means no loss of gas to atmosphere under normal operation Fully automatic controls are designed for simple, unmanned compressor operation Complete set of safety trips and indicators, all wired to explosion proof and intrinsically safe terminal boxes, which simplifies installation Installation is made quick and simple through the use of flexible connections and the single outlet manifold for all pressure safety valves.

PRODUCT RANGE

DELIVERY PRESSURE 250 BAR G

2000 1000

Gazpack 70

Gazpack 50 Gazpack 42 Gazpack 42 High Inlet* Gazpack 37 High Inlet

200 100 Capacity (m3/hr)

Gazpack 37

Gazpack 9

Gazpack 7

Gazpack 5

10 0 Inlet Pressure (bar g) 0.1 0.2 1 2 10 20

*In Development

NOTES TO TECHNICAL DATA: Ambient temperatures: -10C to 45C. Performance figures are typical and are not the full range available. Performance temperatures are based on gas inlet temperature of 20C and 15C cooling water temperature and referenced to 1.013 bar absolute. Flow rates (FGD) measured in accordance with ISO 1217:1996. Flow rates for radiator cooled packages will be reduced. Delivery pressure of 250 bar g is typical. Delivery pressures up to 350 bar g are available. Performances on electric motors are based on a 50Hz supply. Vehicle numbers based on 12 hour compressor running time at maximum capacity and typical cylinder capacity of 10m3 (forklift), 16m3 (car), 150m3 (bus).

PRODUCTS

08

Gazpack Series 5 7 9
Perfect for forklift trucks
Capacity (FGD) Inlet Gas Pressure 12 60m3/hr 0.015 to 0.4 bar g

The Gazpack 5, Gazpack 7 and Gazpack 9 range offers a compact ready-to-run refuelling package. Contained within a weatherproof acoustic enclosure, the units include a 4 stage air cooled compressor, gas recovery vessel, filtration and control panel. These modular packages can also be combined with dispensers, storage and safe area controls.

TECHNICAL DATA
Model Motor Power (kW) Compressor Speed (rpm) Inlet pressure (bar g) GAZPACK 5 GAZPACK 7 GAZPACK 9

4 1500

11 1500

15 1800

18.5 1800

22 1800

FGD Capacity (m3/hr) @ 250 bar g delivery pressure

72
12 21 24 25 28 30 25 28 30 33 36 44 48 52 55 56*

0.015 0.1 0.2 0.3 0.4

60

43

45

DIMENSIONS & WEIGHT

Gazpack 5 745mm W x 1250mm D x 1925mm H Gazpack 7 870mm W x 1293mm D x 2045mm H Gazpack 9 970mm W x 1900mm D x 2260mm H

27
800kg 875kg

9 1

14 3 5

1,650kg

*1630 rpm

GAZPACK 5

GAZPACK 7

GAZPACK 9

NUMBER OF VEHICLES FILLED IN A 12 HOUR PERIOD

09

PRODUCTS

Gazpack Series 37 42
Ideal for medium sized refuelling stations
Capacity (FGD) Inlet Gas Pressure 164 558m3/hr 0.015 to 6.8 bar g

The Gazpack 37 and Gazpack 42 multistage water cooled compressor packages offer reliability and increased capacity for medium sized stations. As modular units, the Gazpack 37 and 42 can be supplied as simple skid mounted blocks through to fully packaged systems with cooling systems, recovery vessels and filtration within acoustic enclosures.
Fully packaged Gazpack 37 with integral storage and control room.

TECHNICAL DATA DIMENSIONS & WEIGHT

Gazpack 37 minimum specification block 2346mm W x 1415mm D x 1437mm H 2,200kg
Model Motor Power (kW) Compressor Speed (rpm) Inlet pressure (bar g) GAZPACK 37 GAZPACK 42

55 1800

75 1800

90 1800

110 1500

132 1500

670 419 384 240 45 26

FGD Capacity (m3/hr) @ 250 bar g delivery pressure

Gazpack 42 minimum specification block 2424mm W x 1922mm D x 1418mm H 3,250kg Gazpack 37 or 42 with acoustic enclosure 2200mm W x 5500mm D x 2400mm H 8,000kg

0.015 0.35 0.55 0.68 1.0 2.0 3.5 5.5 6.0 6.8
*1500 rpm 1590 rpm

164

164 217 249 270 283

164 217 249 270 320

282 377 429 471 553

128 195 291 250*

210 319 464 500 558

150 kW In

GAZPACK 37

GAZPACK 42

45kW

development

NUMBER OF VEHICLES FILLED IN A 12 HOUR PERIOD

PRODUCTS

10

Gazpack Series 50 70
Recommended for large bus and truck fleets
Capacity (FGD) Inlet Gas Pressure 170 1748m3/hr 1.0 to 18.0 bar g

The Gazpack 50 and Gazpack 70 series multistage air cooled compressors offer larger capacities and higher inlet pressures for maximising gas mains pressure and thereby providing energy efficiency savings. These are modular packages with optional air blast cooling, gas recovery system, filtration, baseframe and weatherproof acoustic enclosure.
Fully packaged Gazpack 70 with external storage and dryer.

TECHNICAL DATA
MODEL Inlet pressure (bar g) FGD Capacity (m3/hr) Stages Compressor Speed (rpm)

1.0 4.0 10.0 15.0 18.0 1.0 4.0 10.0 15.0 18.0 1.0 4.0 10.0 15.0 18.0 1.0 4.0 10.0 15.0 18.0
110 kW

169 225 257 294 317 442 533 612 838 955 493 557 751 896 909 809 962 1334 1469 1748
250 kW

5 4 3 3 3 5 4 3 3 3 5 4 3 3 3 5 4 3 3 3

1035 781 1231 977 1101 1475 1475 1475 1475 1475 1301 1093 1093 1318 1475 1475 1475 1475 1475 1475

GAZPAC 50 (45 kW)

2098

1311 1146 DIMENSIONS & WEIGHT

Gazpack 50 with acoustic enclosure 2400mm W x 5900mm D x 2400mm H 8,000kg Gazpack 70 with acoustic enclosure 2400mm W x 7250mm D x 2600mm H 12,000kg GAZPACK 50 GAZPACK 70

GAZPAC 50 (132 kW)

716

GAZPAC 70 (132 kW)

140 76

*Direct Drive Only

GAZPAC 70 (225 kW*)

NUMBER OF VEHICLES FILLED IN A 12 HOUR PERIOD

11

ANCILLARIES

Ancillaries
CompAir offers all the ancillaries required for a fully operational refuelling station: Storage Priority Panel Dispensers - fast fill and time fill options Controls Dryers Electronic access Remote access Gas detectors Dew point monitors

Cascade storage systems

A Fast Fill refuelling system provides gas on demand using a combination of the compressor and prepressurised storage to maximise a 200 bar fill for the vehicle. There are three key elements: Priority Panel, Cascade Storage (typically 3 banks - High, Medium and Low) and Electronic Dispenser. The Priority Panel prioritises the use of gas from the compressor to the Cascade Storage: firstly to the High Bank, then the Medium Bank and finally the Low Bank. The Electronic Dispenser draws on gas from the storage in reverse order (Low, Medium, High) and finally directly from the compressor if demand has exceeded the storage capacity. This system maximises vehicle fill and station capacity and is recommended for public stations.

Storage
CompAir offer a variety of storage systems designed specifically to local standards. All vessels and cylinders can be designed to meet ASME, DOT and TPED specifications and are fully weatherproof removing the need for enclosures, although enclosures are available on request.

STORAGE TYPICAL SPECIFICATIONS

80 litres water capacity per cylinder Compressor feed lines 12mm OD 316 stainless steel tubing & fittings Dispenser bypass line 16mm OD 316 stainless steel tubing & fittings Mechanical valves set storage bank filling priority Maximum working pressure 350 bar g Gauges fitted to compressor feed line and all storage bank lines Lightweight panel with flexible mounting options

ANCILLARIES

12

Dispensers
A full range of electronic and manual dispensers are available, with simple manual operation or fully automatic dispensing with card access technology.

Dryers
Natural gas vehicles require high quality clean gas to ensure long life and minimum maintenance. CompAir offer a range of dryer systems to ensure full protection for the vehicle and the refuelling station. Options include both Low Inlet dryers (precompression) and High Inlet dryers (post-compression). High Inlet dryers are available as static or re-generative systems. The choice of dryer is affected by dew point, inlet pressure and compressor flow rate.

TIME FILL POSTS

Includes fuelling valve, pressure gauge, hose and connector assembly Cost effective with high reliability Unmanned operation once connected Can lower energy costs through use of cheaper off peak energy rates No need for storage systems Ideal for depot based overnight refuelling with modest daily mileage

MANUAL FAST FILL DISPENSERS

Single or dual hose designs with Breakaway safety connections NGV1 or NGV2 nozzles available 1 3 bank sequencing options Ideally suited for single car dispensing or as a backup dispenser at a refuelling depot

ELECTRONIC FAST FILL DISPENSERS

Flow rates up to 80kg/min Single or dual hose designs with Breakaway safety connections NGV1 or NGV2 nozzles available Coriolis mass flow meter Explosion proof and intrinsically safe electronics 1 3 bank sequencing options Suitable for electronic card access and payment systems and stations with high speed filling requirements

Controls
CompAir is able to provide a full range of control systems from simple manual controls to complete systems, with optional PLC, designed for unmanned operation. Control systems can be mounted remotely or within the canopy and are designed around local and national standards ensuring full compliance with regulations. CompAir can also offer remote monitoring capabilities. This provides useful data from the installation which can help to devise more efficient ways of working, including energy conservation, early fault diagnostics and shutdown planning.

13

AFTERMARKET

Aftermarket
The choice of equipment and the overall station design are two key elements which help to maximise availability of refuelling at a CNG station. The third critical element is preventative maintenance and full service support.
With more than 300 CompAir service engineers in over 20 countries, CompAir prides itself on offering global expertise and experience with truly local backup and support. CompAir also has a strong distributor network with in-house CompAir trained service engineers. CompAir offers a comprehensive Aftermarket service designed to fully support the running of a CNG station, including:

Training
CompAir have the ability to undertake CNG training all around the world including customer operator training, installation & commissioning training, and on-going service and maintenance training, either in-house or at the customer's premises.

In-house service engineers Installation and commissioning Extended warranty Long term service contracts Refurbishment Servicing and supply of genuine spare parts Training

GLOBAL PRESENCE

14

Global Expertise, Local Service

COMPAIR OFFICE OR DISTRIBUTOR COMPAIR MANUFACTURING OR PACKAGING PLANT

Reference list
ACTION BUSES / AUSTRALIA ANUDIP GROUP / BANGLADESH BARLOWORLD MATERIALS HANDLING / UK BBA CONNEX GROEP / NETHERLANDS BEIJING HUAYOU UNITED GAS DEVELOPMENT CO. LTD / CHINA BRISBANE CITY COUNCIL / AUSTRALIA GASCO OIL (PAKISTAN) LTD / PAKISTAN CH JONES (KEYGAS) LTD / UK CHARLES DE GAULLE AIRPORT / FRANCE CONNEX / FRANCE FIAT / POLAND GAS AUTHORITY OF INDIA / INDIA GAZ DE FRANCE / FRANCE GOTEBORG ENERGI / SWEDEN HANJIN CITY GAS COMPANY LTD / KOREA H.S ENTERPRISE / BANGLADESH OIL & NATURAL GAS CORP / INDIA VEOLIA PROPRETE / FRANCE PALL-EX / UK PETROBAS / BRAZIL PETRONAS / MALAYSIA POLISH OIL & GAS COMPANY / POLAND QANTAS FREIGHT / AUSTRALIA SAFEWAY CNG / PAKISTAN STADTWERK WURZBURG / GERMANY

Shanghai CompAir-Dalong HP Equipment Co. Ltd

Established in Shanghai China in 2004, Shanghai CompAir-Dalong HP Equipment Co. Ltd (SCDL) is a joint venture between CompAir Group and Shanghai Electric Corporation Group. The company was established in China to manufacture a range of refuelling packages predominantly for Asian CNG markets, combining CompAir's global expertise and their advanced compressor technology with strong local knowledge, support and service capabilities. A separate brochure for SCDL is available on request or from our website www.CompAir.com

sales.ipswich@CompAir.com www.CompAir.com
CompAir policy is one of continuous improvement and we therefore reserve the right to alter specifications and prices without prior notice. All products are sold subject to the Companys conditions of sale. Brochure re-order ref: 98700-550E v2, 10/2006