CNG refueling station construction procedure
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Procedure for Building CNG Refueling Stations I. Site Selection (1) The owner should be familiar with the policies and standards governing station construction. The site should be located in an urban area or along main traffic routes, near sources of water, electricity, and gas, as well as near vehicle traffic, to facilitate refueling. It should also meet the fire safety, environmental protection, and safety requirements specified in urban planning and relevant standards, thereby allowing for a preliminary selection of the site for building the station； (2) CNG authorities (CNG experts), the Construction Commission, planning departments, fire protection agencies, environmental protection agencies, and design teams are stationed at the site. (3) Go to the land administration department to handle the procedures for land expropriation and obtain the land use certificate: (4) Go to the planning department to obtain the planning permit for land use and the construction permit. II. Project Approval (1) The owner submits an application to the local CNG industry management department or planning commission to establish a station ； (2) Provide relevant documents: project proposal, feasibility study report, site selection report ； (3) Approval for project initiation by the competent authority or planning commission for the CNG industry. III. Design (1) Before the preliminary design, the owner provides the design agency with various documents: topographic maps of the site, information on the properties of natural gas, meteorological data, seismic data, information regarding water, electricity, and gas supplies, details on the scale of the facility to be built, preliminary selections for equipment, geological survey data, environmental impact assessment reports, and information related to cultural heritage surveys. (2) Preliminary design by a Class A design firm: general layout ； Architectural style and design of individual structures (aerated sheds, station buildings, etc.) ； Rendering of CNG refueling station ； Main equipment configuration ； Total project cost ； Preliminary design for water, electricity, and gas systems ； Indicate whether it complies with **standards and urban planning** ； Whether the fire protection, environmental protection, safety, and other aspects of the gas station meet the standard requirements. (3) Preliminary design review: The CNG regulatory authority (CNG experts), the Planning Commission, the Construction Commission, planning departments, fire safety agencies, environmental protection agencies, safety offices, designers, and the project owner participate in evaluating the preliminary design. (4) The CNG regulatory authority or the Construction Commission issues opinions on the preliminary design review ； (5) Construction drawing design: The design agency uses this as a basis to carry out designs for the process, overall layout, architecture, structure, electrical systems, water supply and drainage, as well as heating and ventilation systems for the CNG refueling station, and produces the construction blueprints. IV. Application for approval: (1) Submit the preliminary design to the fire department and environmental protection authorities for review; obtain their approval opinions, and have the safety office issue the certificate for simultaneous implementation of safety measures ； (2) The preliminary general layout plan (including the approval comments from the fire safety, environmental protection, and safety departments) is submitted for planning review; surveys are conducted and boundary lines are marked ； (3) Apply for a project planning permit ； (4) The Construction Commission issues the project construction permit ； V. Construction (1) Conduct bidding for equipment, civil works, installation, water, electricity, and gas projects as well as supervision services, and sign contracts ； (2) Obtain a quality inspection authorization letter at the quality inspection station ； (3) Go to the Construction Commission for contract verification ； (4) Organize construction. VI. Acceptance (1) Conduct quality inspection of the project and issue a quality inspection report ； (2) Conduct individual inspections for fire protection, safety, environmental protection, pressure vessels, etc., and issue individual inspection reports, safety assessment reports for hazardous chemicals, lightning and static electricity prevention inspection reports, as well as environmental protection assessment reports ； (3) Obtain a license for the handling of chemical hazardous materials from the work safety supervision department, as well as a permit for the use of pressure vessels and a registration certificate for filling operations from the quality supervision bureau ； (4) The quality inspection department calibrates the air inflation machines and issues a permit for their use in measurement purposes ； (5) Employees go to the relevant departments for technical training to obtain a work permit ； (6) Trial operation, acceptance and rectification, improvement ； (7) Before the comprehensive acceptance: The owner shall prepare relevant documents such as the application for completion acceptance report, relevant approval documents, design documents, construction documents, completion documents, quality inspection documents, supervision documents, material testing documents, financial settlement documents, management systems, and emergency plans for accident handling. (8) The CNG regulatory authority takes charge of the process, with participation from the Construction Commission, planning departments, fire safety agencies, environmental protection agencies, safety offices, quality supervision agencies, CNG experts, as well as the designers and project owners, in order to prepare the completion acceptance report ； (9) Obtain a gas operation license from the CNG industry regulatory authority, a business license from the public administration and commerce bureau, and a qualification certificate for gas stations from the gas management authority ； (10) Commence operation.
Classification of Natural Gas Vehicle Refueling Stations I. Concept A natural gas vehicle refueling station refers to a location or device that fills natural gas vehicles with natural gas, either in a fixed or mobile manner. In English, it is called Refuelling Stations. II. Classification: (I) Fast-charging CNG refuelling stations – these are sites where natural gas is compressed to 25 Mpa in order to quickly refill natural gas vehicles. In English, it is called CNG Quick Filling Stations. (1) Fixed stations: These are located in fixed sites; natural gas is compressed to 25 Mpa using compressors and stored in high-pressure tanks, from where it is supplied to vehicles through filling units. CNG Filling Stations (2) Skid-mounted stations: CNG filling stations in which the equipment and devices related to gas filling are installed on a skid. CNG Skid-Mounted Filling Stations (3) Mobile stations: These are mobile gas filling vehicles in which the equipment and devices related to gas filling stations are installed on a vehicle; by connecting them to gas and electricity at different locations as needed, they can be used to fill cars with gas. In English, it is referred to as CNG Mobile Filling Stations (4) – Mother and Daughter Stations: A system used in areas or cities where there are no natural gas pipelines, where large CNG trailers are employed to transport natural gas from a supply station (referred to as the mother station) to multiple stations where vehicles can be refueled (referred to as daughter stations). CNG MD Filling Stations (5) Underground stations: In large cities where land is scarce, CNG filling stations are built underground, with vehicles being refueled at the surface. CNG Underground Filling Stations (6) Roof stations: In crowded large cities, these are CNG filling stations that are located on rooftops, where vehicles are refueled from the ground level. CNG Roof-Mounted Filling Stations (7): Stations where fueling and gas filling facilities are located in the same place. In English, it is CNG/Diesel Filling Stations. (II) Slow-charging CNG filling stations – these are CNG stations where vehicles gather together, and gas is filled directly into the cars at night or when the vehicles are not in use, using only compressors. CNG Slow Filling Stations: (1) Parking lot slow charging stations – These are CNG stations installed in parking lots where vehicles are concentrated, and they use compressors to fill cars with gas directly at night or when the vehicles are not in use. (2) Small gas filling device: A small, slow gas filling device for filling household cars. In English, it is Small CNG Filling Stations (III). LNG filling stations – stations that use liquefied natural gas to fuel vehicles. In English, it is LNG Filling Stations. (1) Direct liquefaction LNG stations: Stations where natural gas is directly liquefied on-site to fuel vehicles. (2) LNG stations that do not liquefy directly: Stations that transport already-liquefied natural gas to the site for storage and then use it to refuel vehicles. (IV) L-CNG refueling station – a station that vaporizes liquefied natural gas and uses it in CNG form to refuel vehicles. In English, it is L-CNG Filling Stations. (1) Direct liquefaction LNG stations: Stations where natural gas is directly liquefied on-site to fuel vehicles. (2) LNG stations that do not liquefy directly: Stations that transport already-liquefied natural gas to the site for storage and then use it to refuel vehicles.
Equipment list for CNG master station (daily production capacity: 60,000–100,000 cubic meters); total cost approximately: 5.8 million yuan.
Serial Number | Project Name | Project Details | Main Equipment and Configurations | Quantity
1 | Gas distribution system | Raw natural gas buffering, pressure regulation, filtration, separation, metering | Natural gas filtration and separation buffer tank (10 m³), valves, accessories, pressure regulators, flow meters – 1 set
2 | Compression system | D-type compressor, model D-25.5/6-250; exhaust volume: 1,530 m³/h (0.6 Mpa); motor power: 280 KW | 1) Compressor unit, oil-water separator, check valve, drain valve, safety valve, explosion-proof motor, lubricating oil pump, oil injector, specialized tools, spare parts, technical documents – 3 units; 2) Skid-mounted bases – 3 units
3 | Cooling system | Air-cooled, high-efficiency, quiet cooling units – 3 sets
4 | PLC control cabinet | Fully automatic PLC control cabinet: soft start, automatic start/stop, automatic drainage; logic controller from Siemens, key components from Schneider – 3 units produced per day
5 | Sequence control panel | Fully automatic control; valves from Siemens Germany and ARIEL USA – 1 unit
6 | Drying system | Deep dehydration and drying of natural gas (post-stage high-pressure deep dehydration to ensure no free water present); processing capacity: 1,500 Nm³/h. Regenerative high-pressure natural gas deep dehydration units, model CNG1500/25: coolers, separators, heaters, oil removers, regenerative coolers, working towers, pipelines, and valves (key valves imported from the USA and Germany) – 3 sets
7 | Gas storage system | Gas storage tanks, each with a water capacity of 3 m³ – 3 tanks
8 | Gas filling columns | Equipped with imported valves and flow meters – 3 units
9 | Waste gas recovery system | Drainage and recovery of oil and gas; natural gas recovery tank (2 m³) and natural gas wastewater tank (1 m³), including stop valves, safety valves, accessories, technical documents – 1 set
10 | High-pressure gas pipeline system | High-, medium-, and low-pressure pipeline systems within the gas station; all piping, valves, and instruments are installed according to the design drawings. 1 set: 11 Low-pressure gas pipeline system – the low-pressure piping system used in gas stations (including pipes, valves, and instruments). 1 set: 12 Cables for process equipment – 600 meters of ordinary VV-type cables (armored). 1 set: 13 Alarm, detection, and analysis instruments – gas concentration alarm devices, moisture detectors. 1 set: 14 Installation, commissioning, and testing – labor costs for installation, testing fees, travel expenses, and costs related to installation and commissioning. 15 Packaging, lifting, transportation, and installation scope: Water route (in the case of water cooling): from the cooling tank to the end of the process cooling circulation system required by the compressor; Electrical circuit: from the compressor’s PLC control cabinet to all the power and control circuits of the equipment at the gas station; Gas route: from the first natural gas valve provided by the client after it enters the station to the gas dispensers. List of equipment for the CNG substation (daily production capacity: 15,000 to 24,000 cubic meters). Total number of items: approximately 2.2 million. Specifications: Natural gas compressor XD-11/35-250, with a displacement of 1,200 m3/h and a gas extraction efficiency of over 90%; piston rings, gas valves, and packing are all original imported components from Austrian company Holzmeister. 1 gas unloading column; 1 set of gas storage cylinders (V=2 m3; this volume can be increased as needed); 2 gas dispensers, equipped with dual nozzles (imported flow meters and valves); 3 vertical sewage tanks, with a volume of 1 m3 each and a diameter of DN800 mm. Installation and commissioning include valves, pipelines, cables, etc. Transportation and lifting. Brief description of the substation’s process flow: Compressed natural gas from the trailer enters the compressor through the gas unloading column, and then, via a priority control system, it flows sequentially to the gas dispensers, high-pressure cylinder sets, and medium-pressure cylinder sets. First, the compressed natural gas in the trailer flows directly to the high and medium pressure gas storage cylinders used at the station. Once pressure equilibrium is achieved, the compressor starts up to increase the pressure in these high and medium pressure cylinders to 25 MPa. When a vehicle comes to refuel, the cylinders in the trailer supply gas to the vehicle first; once the pressure and flow rate decrease, the system automatically switches to drawing gas from the high and medium pressure cylinders at the station. If the pressure in the station’s air storage cylinders is low, the compressor starts up and directly supplies gas to the vehicle that is being refueled.
Serial Number | Project Name | Project Details | Main Equipment and Configurations | Quantity
1 | Gas distribution system | Raw natural gas buffering, pressure regulation, filtration, separation, metering | Natural gas filtration and separation buffer tank (10 m³), valves, accessories, pressure regulators, flow meters – 1 set
2 | Compression system | D-type compressor, model D-25.5/6-250; exhaust volume: 1,530 m³/h (0.6 Mpa); motor power: 280 KW | 1) Compressor unit, oil-water separator, check valve, drain valve, safety valve, explosion-proof motor, lubricating oil pump, oil injector, specialized tools, spare parts, technical documents – 3 units; 2) Skid-mounted bases – 3 units
3 | Cooling system | Air-cooled, high-efficiency, quiet cooling units – 3 sets
4 | PLC control cabinet | Fully automatic PLC control cabinet: soft start, automatic start/stop, automatic drainage; logic controller from Siemens, key components from Schneider – 3 units produced per day
5 | Sequence control panel | Fully automatic control; valves from Siemens Germany and ARIEL USA – 1 unit
6 | Drying system | Deep dehydration and drying of natural gas (post-stage high-pressure deep dehydration to ensure no free water present); processing capacity: 1,500 Nm³/h. Regenerative high-pressure natural gas deep dehydration units, model CNG1500/25: coolers, separators, heaters, oil removers, regenerative coolers, working towers, pipelines, and valves (key valves imported from the USA and Germany) – 3 sets
7 | Gas storage system | Gas storage tanks, each with a water capacity of 3 m³ – 3 tanks
8 | Gas filling columns | Equipped with imported valves and flow meters – 3 units
9 | Waste gas recovery system | Drainage and recovery of oil and gas; natural gas recovery tank (2 m³) and natural gas wastewater tank (1 m³), including stop valves, safety valves, accessories, technical documents – 1 set
10 | High-pressure gas pipeline system | High-, medium-, and low-pressure pipeline systems within the gas station; all piping, valves, and instruments are installed according to the design drawings. 1 set: 11 Low-pressure gas pipeline system – the low-pressure piping system used in gas stations (including pipes, valves, and instruments). 1 set: 12 Cables for process equipment – 600 meters of ordinary VV-type cables (armored). 1 set: 13 Alarm, detection, and analysis instruments – gas concentration alarm devices, moisture detectors. 1 set: 14 Installation, commissioning, and testing – labor costs for installation, testing fees, travel expenses, and costs related to installation and commissioning. 15 Packaging, lifting, transportation, and installation scope: Water route (in the case of water cooling): from the cooling tank to the end of the process cooling circulation system required by the compressor; Electrical circuit: from the compressor’s PLC control cabinet to all the power and control circuits of the equipment at the gas station; Gas route: from the first natural gas valve provided by the client after it enters the station to the gas dispensers. List of equipment for the CNG substation (daily production capacity: 15,000 to 24,000 cubic meters). Total number of items: approximately 2.2 million. Specifications: Natural gas compressor XD-11/35-250, with a displacement of 1,200 m3/h and a gas extraction efficiency of over 90%; piston rings, gas valves, and packing are all original imported components from Austrian company Holzmeister. 1 gas unloading column; 1 set of gas storage cylinders (V=2 m3; this volume can be increased as needed); 2 gas dispensers, equipped with dual nozzles (imported flow meters and valves); 3 vertical sewage tanks, with a volume of 1 m3 each and a diameter of DN800 mm. Installation and commissioning include valves, pipelines, cables, etc. Transportation and lifting. Brief description of the substation’s process flow: Compressed natural gas from the trailer enters the compressor through the gas unloading column, and then, via a priority control system, it flows sequentially to the gas dispensers, high-pressure cylinder sets, and medium-pressure cylinder sets. First, the compressed natural gas in the trailer flows directly to the high and medium pressure gas storage cylinders used at the station. Once pressure equilibrium is achieved, the compressor starts up to increase the pressure in these high and medium pressure cylinders to 25 MPa. When a vehicle comes to refuel, the cylinders in the trailer supply gas to the vehicle first; once the pressure and flow rate decrease, the system automatically switches to drawing gas from the high and medium pressure cylinders at the station. If the pressure in the station’s air storage cylinders is low, the compressor starts up and directly supplies gas to the vehicle that is being refueled.
There is also a safety pre-assessment before the preliminary design is carried out after the project is approved
In some cases, Anping emerges only after installation; it’s rare to see this. Anping is determined by the installation process, which is quite the opposite in such situations
Great material, very comprehensive. Thanks to the original poster.
:kiss: Thank you for sharing! ~
Thank you, OP; I really have met an expert