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Project Report on CNG filling
         Operations


          Ankur Rawal




                                1
CERTIFICATE



      Certified that this project report “CNG filling Operations” at
Indraprastha Gas Limited is the work of “Ankur Rawal” who carried out the
project work under the Operations & Maintenance department.




Mr. Amit Kumar Deb
Manager (CNG - O&M)




Mr. Ujwal Bhandari
General Manager (CNG-O&M)




Mr. P.K. Pandey
Chief General Manager (CNG-O&M)




Mr. Manjeet Singh
Vice President (E&P)




                                                                            2
ABSTRACT


   Filling operations of Compressed Natural Gas (CNG) in Natural Gas Vehicles

       Natural gas is being used as an alternative fuel to gasoline. Natural Gas vehicle
(NGV) refueling stations incorporate a series of processes which make the gas
dispensable. The report focuses on understanding various aspects of these processes
and test and suggest changes in their functioning.


       Various tests and observations were made on the compressor and inlet pipes
and pressure drops calculated. Useful characteristics of CNG during the fill process are
temperature, pressure, and flow rate, as well as, total volume dispensed. CNG is
dispensed to an NGV through a process known as the fast fill process, since it is
completed in less than five minutes. The system is being constantly upgraded in order
to result in lower filling time and make it comparable to that of petrol or diesel fillings.


       The report also highlights the quality control operations at Indraprastha Gas
Limited (IGL). The Gas Chromatography installation at Mahipalpur Gas Station has
been carefully studied along with viscosity relations with dilution were done for snoop
solution used to test leakage.




                                                                                               3
Acknowledgments

       I wish to acknowledge all the people who have helped me finish this Report.
Without the generosity of others there is no way that I could have finished it. The report
is an outcome of the advice and tutelage of several people who work at Indraprastha
Gas Limited (IGL).

       I would like to thank my advisor and mentor Mr. Ujwal Bhandari (General
Manager CNG-O&M), first of all, for being so patient with me and being an excellent
mentor throughout my time in IGL. Without the advice and knowledge of Mr. Bhandari,
the completion of this document would have been impossible. The other guides of my
endeavor, Mr. Amit Kumar Deb (Manager CNG-O&M Jail Road Control Room) and
Mr. Abhinav Sahay (Additional Manager CNG-O&M Lado Sarai Control Room)
have also been very helpful for advice and knowledge of subjects contained in this
report. The entire team of Engineers and Technicians at Jail Road and Lado Sarai
Control Rooms have in some way or the other helped me understand practical aspects
of whatever I had learnt in texts earlier.

       I am highly indebted to Mr. Manjeet Singh (Vice President – E&P) for he
believed in my objectives of undergoing this internship and made an exception in
allowing me to be a part of the organization after completing the second year of my four
year graduation in Chemical Engineering.

       My college, USCT has been very supportive as well, to have allowed me to use
their facilities and equipments for a few tests. University Professors such as
Dr. Biswajit Sarkar have helped me with the required textbooks and constantly
answered all my queries regarding fluid dynamics and Heat Exchangers.




Thanks and Regards,




                                                                                             4
AN OVERVIEV OF INDRAPRASTHA GAS LIMITED


COMPANY PROFILE


       Indraprastha Gas Limited (IGL), a Joint Venture of GAIL (India) limited and BPCL
along with the government of NCT of Delhi was incorporated on December 23, 1998 to
implement the compressed Natural gas (CNG) expansion program and the Piped Natural Gas
(PNG) project for varied application in the domestic and the commercial sector.

       In 1999, IGL took over the Delhi City Gas distribution Project started by GAIL (India)
Ltd. which focused on supply and distribution of CNG & PNG in the capital city. Thereafter IGL
worked tirelessly to take the project to new heights.




IGL’S VISION

       -‘To be the leading clean energy solution provider, committed to stakeholder
value enhancement, through operational excellence and customer satisfaction’



This vision statement signifies five major attributes of the organization.

       Commitment to the environment
       Providing complete energy solution and thereby going beyond CNG for transport and
       PNG for cooking application
       Enhancing value for beneficiaries including customers, stakeholders and employees
       Achieving excellence in operations
       Providing satisfaction to customer




                                                                                                 5
CNG-Compressed Natural Gas


        Natural Gas is a combination of Methane, Propane and Butane. Conventional Natural
Gas exists above crude oil deposits, and is often wasted or burned in the oil collection process
due to the high costs of capturing and using it. When the gas is burned, it prevents the Methane
from reaching the atmosphere. Carbon Dioxide into the atmosphere is less harmful than
Methane.
        Natural Gas produces less air pollution than any other fossil fuel. Use of CNG vehicles
can reduce Carbon Monoxide emissions as much as 93% Nitrogen Oxide reduces about
33% and Hydrocarbons are reduced by about 50%. Natural Gas emits almost no carcinogenic
particulates.
        By using CNG to power vehicles a bi-fuel tank can exist; therefore, in locations without
CNG pumps, Petrol may be used by just flipping a switch. Since CNG is a clean-burning fuel,
maintenance costs are lowered. CNG is 130 octanes, which is considerably higher than 93
octanes for Petrol; consequently, the CNG vehicle is more energy efficient. Besides using
Natural Gas to power vehicles, it can also create electricity and heat homes and commercial
buildings.
        Compressed Natural Gas (CNG) is natural gas that has been compressed for storage
aboard a natural gas vehicle (NGV), a vehicle whose engine is fueled by Natural Gas. Natural
gas is compressed to high pressure (200 bar/20.7 MPa or higher) to most effectively utilize the
NGV’s limited available space for storage.


        ADVANTAGES                                         DISADVANTAGES
        Abundant Supplies                                  Nonrenewable Resource
        Low Emission Vehicles                              Decreased Range
        Advanced Vehicle Developments                      New Refueling Sites Required
        Reduced engine maintenance                         Expensive Engine
        Modifications Inexpensive




                                                                                                   6
It is proven manifold that natural gas is a very clean fuel. The world Energy
Conference of Tokyo 1996 announced that natural gas is the No.1 alternative because:


1. Natural gas has excellent combustion properties,
2. Natural gas is a safe fuel (lighter than air, high ignition temperature),
3. Natural gas is a clean fuel (no sulphur, no lead, no particles, little NOx, CO and HC).
4. Natural gas has abundant reserves, wide spread over the globe.
5. Natural gas is a strategic fuel,
6. Natural gas is cheap if we exclude taxes.




Natural Gas Vehicle (NGV) Basics


        Natural gas used in vehicles is no different than natural gas used in residential or
commercial markets, except that it is compressed to high pressures for storage purposes.
Compressed natural gas (CNG) is gas compressed to pressure generally ranging from 200 to 259
bar (20.7Mpa to 25Mpa). At the dispenser, Natural Gas is delivered into vehicles either by
weight (in kilograms) or by Gasoline liter equivalents (GLE – an energy equivalent comparison
to gasoline) and carries an octane rating between 122 and 130.
        There are many types of natural gas vehicles (NGV’s), including dedicated, Bifuel and
dual fuel models. There are distinguished by whether the engine runs only on natural gas
(dedicated), operates on either natural gas or gasoline (Bifuel), or simultaneously burns a
combination of both liquid fuel (such as Diesel or Petrol) and natural gas (dual fuel).
        CNG is stored onboard a vehicle in several types of pressurized vessels that conform to
industry-recognized standards for installation (the NGV 2 standard in Canada & USA or OISD
Standard 226 for City Gas distribution in India)
        If NGV’s and equipment are in sound condition, you can expect them to perform reliably
when they are well maintained by a trained technician and drivers are well informed and trained.




                                                                                                   7
Although conventional wisdom holds that natural gas engines should require fewer oil
changes and perhaps even less frequent scheduled maintenance because of less carbon build-up,
regular maintenance of the vehicle, engine and/or conversion system will ensure the superior
performance of the NGV versus its gasoline and diesel counterparts.


       A CNG fueling facility typically consists of a compressor, storage Cascades and a
dispenser system. Dispensers come in two types: fast fill, which delivers fuel at a rate
comparable to gasoline or diesel systems, and time fill, which fuels vehicles over a period of
time. The actual fueling of an NGV is similar to fueling with gasoline or diesel.




CNG Quality Control

       An extensive quality control of the incoming Natural Gas for Refueling in the city of
New Delhi is done at the Mahipalpur CNG Station, which comes under the Lado Sarai
Control Room. A Gas Chromatograph monitors and records the quality of the Natural Gas at
all hours of the day all round the year. It measures quantitatively the %composition of various
components of the Natural Gas, which further helps in maintaining exact desirable proportions.

       The incoming Gas from GAIL is odorless and therefore, a smelling agent (Ethyl
Mercaptin and Methyl Mercaptin) is mixed into the Gas at IGL’s Patparganj Plant. Where the
smelling agent is introduced at traceable quantities as the concentration magnifies when
compressed. A detailed functioning of the Gas Chromatograph is explained further.

       Major contents of the Quality control are: %Composition of C 1 - C6& above, Gross
Calorific Value, Net Calorific Value and specific volume.

       As the Gas upon combustion releases water in the form of vapor, this water vapor
releases more heat in the process of condensation. This heat when added to the Gross Calorific
value (GCV) of the fuel is known as the Net Calorific Value (NCV).

       Specific Volume is the volume of Gas occupied by 1 Kg of Gas at Standard Temperature
and Pressure (STP).




                                                                                                  8
Gas Chromatograph (GC)

       In a Gas Chromatogram (GC) Analysis, 0.1-10µL (micro liter) of a mixture of
compounds is injected into a heated Injector, where all of the compounds vaporize. A gentle
stream of the Carrier Gas, Helium (He) moves the entire mixture onto the Collumn, the
corresponds of the mixture separate as they pass through the column. The process can be
considered as an exceptionally good Fractional distillation using a superb fractionating column.




                        Figure 1: Schematic representation of the components of a GC



The Process


       The separated compounds pass from the column into a detector that produces an
electrical signal proportional to the amount of compound passing through the detector. A
recorder provides a graph. The Gas Chromatogram is plotted against the detector Signal versus
Retention time. The Gas chromatogram shows a peak for each compound in the mixture. The
retention time can be measured from the Chromatogram. An Integrator measures the areas under
the peaks in the Gas Chromatogram.


                                                                                                   9
Thermal Conductivity Detector (TCD)




                                                                                Flame Ionization Detector (FID)




                                     Figure 2 detectors used in Gas Chromatography




The Chromatogram


       A chromatogram consists of a base line and a number of peaks. The area of a peak allows
quantitative determinations. Starting point of a chromatogram is the time of injection of a
dissolved sample. The time interval between a peak and the point of injection is called retention
time tR. A component can be identified by its retention time (qualitative determination).
       The retention time is the sum of the residence time of a solute in the mobile phase (t 0) and
in the stationary phase (t R' = net retention time); t 0 is also known as dead time. It is the time
required by a component to migrate through the chromatographic system without any interaction
with the stationary phase (also called air or gas peak).
       For a given, the area under its peak on the chromatogram is proportional to the amount of
the compound in the sample. Direct comparison of peak areas for different compounds is
unreliable because detectors do not have the same sensitivity to all compounds. For this
reason, a sample of the Natural Gas is maintained in the GC. The Area under the
chromatogram is then compared to that of the sample, and the result is recorded.




                                                                                                              10
Figure 4: Schematic Chromatogram




COMPONENTS   Jan      Feb     Mar     Apr      May      Jun      July
C1            92.7464 92.4233  94.102 91.7059 90.8413      88.64 91.4763
C2             4.0807  4.2759  4.6296   4.3309   4.4206   5.2094   4.3462
C3             0.8629  1.0646  0.7279   0.8726   0.6122   1.3443   0.7145
I-C4           0.1161  0.1541  0.1227   0.0991   0.0232   0.1589    0.058
N-C4           0.1641  0.2225  0.1657   0.1368   0.0003   0.1705   0.0626
N2             0.1745  0.2326  0.1659   0.1904   0.1045   0.0983   0.1364
CO2            1.8521   1.627  0.0793   2.6596   4.0063   4.2942   3.2024
Neo-C5              0       0                0        0        0        0
I-C5           0.0029       0  0.0053   0.0037   0.0008   0.0297   0.0023
N-C5                0       0  0.0015    0.001   0.0007   0.0256   0.0013
C6+            0.0003  0.0001       0        0        0   0.0291        0
GCV           9294.51 9368.78 9476.66 9230.251 9043.145 9257.759 9142.276
SG             0.6059  0.6082  0.5903   0.6145   0.6219   0.6419   0.6164

                  Table 1: GC data Mahipalpur Plant (Period: Jan-July2011)




                                                                             11
C1: Methane
       C2: Ethane
       C3: Propane
       I-C4: Iso-Butane
       N-C4: Normal Butane
       N2: DiNitrogen
       CO2: Carbon Dioxide
       Neo-C5: Neo Pentane
       I-C5: Iso Pentane
       N-C5: Normal Pentane
       C6+: Higher Alkanes
       GCV: Gross Calorific Value (J/mol)
       SG: Specific Gravity (m3/Kg)


Standard Reaction of HC combustion:

                                                ………………….…ΔHr = Gross Calorific Value


Limitations:

       Only compounds with vapor pressures exceeding about 10–10 torr can be analyzed by gas
chromatography mass spectrometry (GC-MS). Many compounds with lower pressures can be
analyzed if they are chemically obtained (for example, as trimethylsilyl ethers). Determining
positional substitution on aromatic rings is often difficult. Certain isomeric compounds cannot be
distinguished by mass spectrometry (for example, naphthalene versus azulene), but they can
often be separated chromatographically.


Accuracy:

       Qualitative accuracy is restricted by the general limitations cited above. Quantitative
accuracy is controlled by the overall analytical method calibration. Using isotopic internal
standards, accuracy of ±20% relative standard deviation is typical.




                                                                                                     12
Difference between Gross Calorific Value and Net Calorific Value:

         The Water produced in the combustion reaction is in the gaseous state. This water when
condensed to liquid state at ambient temperatures in the cylinder releases the Latent heat of
Condensation which unlike the Gross Calorific Value is released from the exhaust when it
interacts with air at ambient temperature. This additional energy is not used for the expansive
working within the piston cylinder and therefore is not accounted for in the actual Calorific
Value of the gas mixture. The Net Calorific Value is what we read in instruments and we
subtract the known value of Latent heat of condensation of steam at given conditions to obtain
the Gross Calorific Value.
         Net Calorific Value (NCV) – Latent heat (condensation) = Gross Calorific Value (GCV)




CNG Refueling Station

         A CNG station is a site consisting of interconnected equipment, which is designed to
compress Natural Gas to a high pressure and either store the CNG (if the site is equipped with
storage) or dispense it directly to a natural gas vehicle for refueling.
         A CNG station typically consists of one or more compressor packages to compress the
Natural Gas, and several additional systems, which include Cascade storage systems, PLC based
controls system such as a priority controller panel, a temperature/pressure compensation panel, a
buffer panel, gas dryers, fast refueling (CAR dispensers) and time refueling (BUS) dispensing
units.
         The Station includes separate areas for Compression, Storage and Dispensing. It includes
Air compressor pipes, Water pipelines etc. It also includes provisions for safety against Fire or
Leakage. The provisions include Carbon dioxide (CO2) Cylinders; Dry Chemical Powder (DCP)
cylinders etc.




                                                                                                    13
CNG Distribution Network

                                        Main line ~18-20 bar

                                                                                               ~18-20 bar
             CNG                                  ~250 bar                                   CNG
          Compressor                                                                      Compressor
                                          Mobile               Mobile
                ~18-20 bar                                                                     ~250 bar
                                          Cascade              Cascade
            Storage                                                                        Storage
MOTHER      Cascade                                                                        Cascade      ON-LINE
STATION         ~200 bar                                                                                STATION
           Dispenser                                                                       Dispenser
                ~200 bar                                                                       ~200 bar
          CNG Vehicle                     Mobile               Mobile                     CNG Vehicle
                                          Cascade              Cascade



                                                               Booster
                                ~200 bar                                       DAUGHTER
                                                             Compressor
                       DAUGHTER
                                                                               BOOSTER
                        STATION
                                                                                STATION
                                         Dispenser            Dispenser
                                                                           ~200 bar
                                        CNG Vehicle          CNG Vehicle

                              Figure 5: Schematic diagram of CNG distribution at IGL


   Type of stations at IGL


          Mother station: It’s a station where a direct gas line received and SCM capacity of
          compressors installed there is more than 1200 SCM and LCV is also filled.
          Online station: It’s a station where online gas line is received from GAIL but the
          capacity is up to or below 1200 SCM. Cascades filling are also there.
          Daughter booster station: It’s a station where compressors are not installed and gas is
          being compressed by means of a device named booster.
          Daughter station: It’s a station where gas is not compressed at the station itself and is
          filled direct from the LCV.




                                                                                                             14
CNG Station Basics


Key CNG Refueling Station Equipment:


       Gas Dryer (inlet or outlet)
       Compressor Package System (bare shaft compressor, inter-stage cooler, piping,
       separators)
           -   Driver (electric motor or gas engine)
           -   Low pressure inlet train
           -   High pressure outlet system
           -   Canopy or housing (weather protection/noise attenuation)
       Cascade Storage System
       Priority Control Panel
       Car Dispenser
       Dispenser (single or double hose, metering or non-metering, trickle, fast fill)




Compression System


       Natural gas is usually transported to the CNG station site from the main Gas Pipeline
provided by GAS AUTHORITY OF INDIA LIMITED (GAIL). This gas can range in pressure
from as low as 12 bar (gauge pressure above atmospheric), to as high as 35 bar/ 3.45 Mpa or
higher. In any case, it is still too low of a pressure for use in vehicle storage systems.
       For this reason, the gas must be compressed. However, prior to compressing the gas, the
incoming gas may need to be conditioned further, so as not to damage the compression
equipment or downstream systems. For example, if the gas is “wet”(has an unusually high
concentration of evaporated water), then the gas will first pass through a dryer, if the Sulphur
contents in the gas is higher, it also should be removed. This is a large vessel, surrounded by
related components, which removes water from the gas stream using a “desiccant” material.



                                                                                                   15
Once the gas is properly conditioned as required, it then enters the compressor. The
compressor is typically the largest and most complex piece of equipment in the entire refueling
station. It raises the pressure of the natural gas to 250 bar (25Mpa), or higher, using a number of
separate stages, which increase the gas pressure in increments.
       The Compressors are typically reciprocating compressors. These are driven in a rotational
manner, with the compressor translating this rotational force into a Piston/Cylinder combination.
       Much like the reverse of an engine, a compressor uses a series of valves to move the gas
into each cylinder, compress it with a Piston, and then discharge in into the next stage at an
increased pressure. The cylinder configurations can either be a “W” or “V” shape, or horizontally
opposed.




Metering Skid


       The first Equipment on the Main Inlet piping is the Metering Skid. It helps monitor
precise Station Inlet GAS characteristics as per requirement up to compressors which helps study
gas loses over compression etc. Flow mater readings help CNG Station Marketing and Sales
Department tally Station reconciliation with respect to sales and also IGL gas reconciliation with
GAIL (India) Pvt. Ltd.


Main Functions:
       Pressure regulation.
       Gas filtration.
       Preventing Pilferage
       Precise metering
       Cross-Checking of metering
       Emergency shut-down of station through Main Isolation Valve




                                                                                                      16
Major Components

     Suction Line Filter
     The Suction Line filter includes protection from moisture, inorganic and organic acid
  resulting from burnout or chemical changes in the system. It also clears away combustible
  dust, which may be introduced through mechanical work done over the Pipeline. It has a 5µm
  Filter for such unwanted particles.


     Slam shut-off valve
     The Slam shut off valve is used in Metering skid for shut off line in case of emergency
  when line pressure is above 23 kg/cm2 or below 13kg/cm2. It is a Butterfly Valve which is
  also called the Main Isolation Valve which may be used to cut-off the whole station from the
  Main Pipeline.


     Pressure regulating Valve
     It regulates the pressure of gas in flow line according to adjustable limit.


     Mass Flow meter
  Mass flow meter is used in flow line to continuously monitor the input mass flow of Gas. It
  uses a Coriolis Type of mechanism for reading Flow rate.

     Pressure and Temperature transmitter
  Pressure transmitter and Temperature transmitter is used to sense Pressure and Temperature
  in line pressure to Flow Boss. A special Differential Pressure meter is installed across the
  Filter, which indicates amount of choking residue on the filter as the pressure drop across it.
  A Differential Pressure of 1 bar or above means that the filter requires cleaning.


     Flow boss (flow computer)
  Each characteristic data such as inlet pressure, temperature, Mass Flow etc. for the Gas at
  Inlet is stored in flow boss to log the data in computer.




                                                                                                    17
F
                                    I
                                    L
                                    T
                                    E
                                    R



                           Figure 6 Schematic diagram of the metering skid




Compressor drive

       The Compressor can be driven either by an Electric Motor, or by a Natural Gas engine.
For an electric motor drive, an electronic device called a starter or soft start applies power to the
motor when the compressor is required to turn on. The motor shaft is coupled to the compressor
shaft either directly, or by means of a belt drive. Typically, larger compressors are direct-driven.
       A compressor package also has a great deal of support equipment associated with the
package. Mechanically, the compressor requires a lubricating oil supply to lubricate the
cylinders, pistons, and other moving parts. It also requires a means to remove from the gas
supply oil that is introduced through lubrication.
       This typically involves a system of filters and separators. Filters are typically placed at
the inlet and the discharge of the compressor itself, while in-line gas separators are placed
between the stages of compression. Separators spin the gas in a circular motion to use
centrifugal force to condense any liquid out of the gas stream. This results in a collection of
condensates, typically water and oil, which must be periodically removed from the separator
vessels. This is typically done automatically in the packages, with collection in the large
recovery tank(s) and later automatically drained into one of the beams in the skid case.



                                                                                                        18
Compressor: Dresser Rand


   •   Maximum Driver HP                    250 (186 kW)
   •   Standard Stroke                      7 inch (178 mm)
   •   Crankshaft Diameter                  3.75 inch (95 mm)
   •   Cylinder Diameter (LP)               4.00 inches
   •   Cylinder Diameter (HP)               3.25 inches
   •   Main Bearing Length                  3.75 inch (95 mm)
   •   Piston Rod Diameter (LP)             1.5 inch (38 mm)
   •   Piston Rod Diameter (HP)             2.25 inch (57.15mm)
   •   Speed                                570 (rpm)

Materials:-

   •   Frame                                Cast Iron
   •   Crankshaft                           Forged Steel
   •   Connecting Rod                       Forged Steel
   •   Crosshead                            Aluminum
   •   Main Bearing                         Aluminum
   •   Crankpin Bearing                     Aluminum
   •   Pin Bushing                          Bronze
          o Crosshead Pin                   Steel Alloy

   •   Design parameters:-

          o Suction pressure                14-22 bar

          o Inter stage compression ratio                  Suction            Discharge

                       Ist Stage:                   3     14-19 bar          45-60 bar

                       IInd Stage                   2     45-60 bar          120-130 bar

                       IIIrd Stage                  2     120-130 bar        220-250 bar

   •   Compressor Flow rate:-               1200 SCMH (916 Kg/Hr) at ideal condition




                                                                                            19
Cooling System



       Compressors generate heat as a natural byproduct of compression. For this reason, they
must be cooled. IGL generally has only air-cooled compressors, which means they employ
forced air-cooling of the compressor and/or gas stream, instead of water cooling like one would
find in a car engine. Some compressor blocks are self-cooling, incorporating a fan onto their
main drive shaft, which forces air over the compressor block and over the compressed gas lines.
Other blocks require separate heat exchangers, which cool the gas after each stage using a
separate fan.
       These Heat exchangers (Inter Coolers) are Shell and Tube with Fins, with multiple passes
in order to result in the desired Temperatures at inlet and outlet for each Stage.




Recovery system


       Another important system is the blow down recovery system. This system, which
includes the recovery tanks and various automated valves, captures the gas from the compression
system when the machines are shutoff, and maintains a closed loop system by containing and
recycling this gas. It also permits the compressor to start and stop “unloaded”, or without
compressing gas, by re-circulating the gas within the compressor on start-up, and on shut-down.
The majority of this gas is captured in the recovery tanks.
       The compression equipment also required a great deal of electronic and electrical control,
as most skids are automated to a high degree. This means that they must have enough
intelligence to turn themselves on, shut themselves off appropriately, and do it all safely, while
watching for possible faults. This is generally accomplished by the electronic controls system
on–board each skid. The vessel is called a Blow Down Vessel (BDV).
       A Knock out drum of 900 litres is provided at suction, supply CNG to the compressor
through flexible hose to suction collector and first stage cylinder. BDV also acts as a condensate
collecting bottle. All the condensate and oil are drained into the BDV.


                                                                                                     20
Gas Flow within Compressor




                                    INTER COOLER               INTER COOLER

        Inlet                                                                                    AFTER COOLER

                                          PT102                    PT103



                                                                                                 PT104
                                                                                          3rd
                                               1st                2nd
   PCV108                  PT101                                                         Stage
                                              Stage              Stage




                   PRV




         BDV

        (Blow
                                                                                                         PRIORITY
        Down
        Vessel)
                                                                                                          PANEL




PT106             Condensate
                                               Figure 7: Schematic layout of Compressor system




                         Natural Gas

                         Package Boundary

                         Condenate (Water + oil)




                                                                                                           21
Mechanism of Compression



                              Expulsion of gas




                                                       Compression
     Expansion of
     residual gas


                                                                       Initial condition




      Clearance
      volume                            Suction stroke
                    Figure 8: PV diagram for Single Stage Reciprocating compressor




                                                         Shaded area
                                                          represents
                                                         net saving in
                                                            energy




                     Figure 9 PV diagram for Multi Stage Reciprocating compressor




                                                                                           22
General Physical Parameters


   •   1st stage suction pressure (Kg/cm2) = 14.95
   •   1st stage discharge pressure (Kg/cm2) = 43
   •   2nd stage discharge pressure (Kg/cm2) = 79.49
   •   3rd stage discharge pressure (Kg/cm2) = 146
   •   1st stage suction temperature (oC) = 37
   •   1st stage discharge temperature (oC) = 125
   •   2nd stage discharge temperature (oC) = 102
   •   3rd stage discharge temperature (oC ) = 96
   •   Gas temperature after cooler (oC) = 52
   •   Lube oil pressure (Kg/cm2 ) = 1.02
   •   Flow meter totalizer reading suction (Kg).
   •   Flow meter totalizer reading discharge (Kg)




Compressor start preconditions


Tag name                     Tag description

PT-101                       1ST Stage suction pressure.

PT-102                       2nd Stage suction pressure.

PT-103                       3rd Stage suction pressure

PT-104                       3rd Stage discharge pressure.

PT-105                       Engine fuel gas pressure.

PT-106                       Blow down vessel pressure

PT-401                       Engine starting air pressure.


                                                             23
GD-501           Gas detector

GD-502           Gas detector

FD- 501          Flame detector

FD-502           Flame detector

TE-101           1st Stage gas suction temperature

TE-102           1st Stage gas discharge temperature

TE-104           2nd Stage gas discharge temperature

TE-106           3rd Stage gas discharge temperature

TE202            Engine Jacket Temperature (oC)

TE-301           Engine lubes oil temperature

TE-108           Engine exhausts gas temperature

TE-208           Compressor cooling oil header Temperature

LSL-201          CW surge tank level low

SSHH-101         Engine over speed contact

Emergency stop   Emergency stop push button

SOV-101 ON       Drain solenoid valve ON

PT-301           Engine lubes oil pressure

PT-302           Compressor lubes system oil Pressure

TE-107           Engine inlet manifold temperature




                                                             24
Priority panel


       The priority panel consists of a priority valves and non return valves, so arranged that
intended use of providing priority to vehicles is achieved. The priority panel is connected to
discharge of compressor at one end and is connected in parallel to cascade (storage) and
dispenser at other end. If there are no vehicles for gas filling, then priority valve directs the gas
flow to cascade.
                                                                     High Bank
                       SOV-110                  PT-110
                                                                    Car cascade



                                                                     Medium Bank
                        SOV-111                  PT-111
                                                                      Car Cascade


                        SOV-112                  PT-112                Low bank

                                                                      Car cascade

                                                                        High bank car
                                   SOV-113               PT-113           dispenser

C
N
                                                SOV-117                Medium bank
G
                                                                       Car Dispenser

                                     SOV-118                           Medium bank
                                                                       Car Dispenser


                       SOV-112                  PT-112                 Bus

                                                                     Cascade

                       SOV-112                    PT-112              Bus Cascade




                                                                         Mobile
                         SOV-112                     PT-112
                                                                          bank            NRV: Non Return valve


                                                                                                        25
LCV Priority Routing

       The Mobile Cascade Vehicles, also known as LCV, are Flatbed trucks on which a
Cascade has been securely tied. These contain about 2200-2400 Liters of Natural Gas at 250 bar.
These are filled at Mother Stations and transported to Various Daughter and Daughter Booster
stations under each Control Room. This movement of LCVs around the city has been outsourced
to various Transport Contractors, who charge on per-km basis. The Job of priority routing arises
in order to minimize the Total number of Kilometers that have to be paid for, while still
providing Gas to the Required Daughter and Daughter Booster Stations.

       Such a Routing is done every time the Contractor revises the Km-Data chart and/or a new
Station comes up under a Control Room. This form of Assignment is a Linear Programming
Problem (LPP), Transportation Problem. The Following Figures Explain the Priority Routing
under Jail Road control room.




                                Figure 10: Suggested Priority routing Chart, data in Kms




                                                                                                   26
Figure 11: Existing Priority chart for Jail Rd Control room


       The Priority Routing involves more parameters than assumed, such as licensing issues
and capacity considerations. Jail Road control room consists of 19 LCVs. 13 of which are
contracted to Chowdhary transport and 6 through Orient Transport. There exist two Daughter
and six Daughter stations under this control room and therefore a well planned and executed
priority route results in considerable monetary and energy savings.




                                                                                              27
Hazardous Area Classification of a CNG Station




                                                 28
Hazardous Area Classification of a CNG Station


        OISD, OIL INDUSTRY SAFETY DIRECTORATE (Government of India, Ministry of
Petroleum and Natural Gas) issues a Safety Standard for the operation and distribution of city
Gas.
        A major aspect of understanding Hazardous Areas is to classify them on the basis of the
surroundings and the kind of materials present. Such classification can be found in the National
Electric Code (NEC), which is a standard for classifying Dangerous locations on operational and
breakdown basis. It also includes dangers from all sorts of materials which may be present such
as foam, plastics, combustible dust, etc.




                                                                                                   29
The Cascade cylinder storage area and the compressor area have been classified as Class
I - Division I as these handle high pressure Natural Gas (Group I), which is present in the
atmosphere at all times of normal functioning and require acute attention in case of a failure or
breakdown.

        The dispensing area has been classified as one which is the most prone to Hazards as vent
gas is always present in considerable quantities, under normal functioning. Under an event of
mechanical failures in the tubing etc. this area would be highly dangerous as the General Public
accesses this area for CNG refilling.

      The Filtration and Metering skid Area is classified as Class II – Division II –Group E,F,G
as combustible dusts of all composition is present in the incoming Natural Gas and proves to be
harmful in case of maintenance operations.




                                                                                                    30
Data for Pressure drop in piping at Suction


                      Buckhardt Compressor date: 25th June2011

                          Engine gas Flow: 24.8888889 Kg/hr

                  Engine Inlet Suction Flow meter: 670.555556 Kg/hr

                    (ρ) Density at 15.07 bar, 29.07oC: 9.483 (kg/m3)

                        Volumetric flow rate: 70.71133 (m3/hr)

                        (Q) Volumetric flow rate: 0.01964 (m3/s)

                          (D) Diameter of pipe (2”): 0.0508 (m)

                              (v) Velocity: 9.695929 (m/s)

                      (T) First stage Suction temperature: 29.07 oC

            (µ) Viscosity of gas at 15.07 bar, 29.07oC: 1.182*10-5 (kg/m.sec)

                    (k) Kinematic viscosity of gas: 1.25*10-6 (m2/sec)

                          (Nre) Reynold’s number: 395194.37




                                     Formulae used

                     Volumetric flow rate: (Mass flow rate)/Density

                            Flow (m3/hr)/3600 : Flow(m3/s)

       Velocity of Flow: Volumetric flow rate/Cross sectional area of Flow (πD2/4)

                     Kinematic Viscosity: Dynamic Viscosity/density

              Reynolds number: (Diameter*Velocity)/kinematic Viscosity


                                                                                     31
32
33
34
Assumptions for Calculations



    Natural Gas is assumed to be 100% Methane, and properties of Methane at Low pressure
    and High Pressures assumed to be properties of Natural gas at the given Pressures and
    Temperatures.
    Moody diagram for coefficient of friction has been linearly interpolated between known
    values to obtain an approximate coefficient for a given Reynolds number and roughness
    factor.
    Pressure regulation Valves (PRVs) etc. equipment at the metering Skid have been
    assumed to result in zero pressure loss.




                                                                                             35
Figure 12: Moody diagram (Ref: College of Nautical Sciences, Glasgow)

                                                                        36
Comparative Data for Pressure Drop in Tubing



                                   Mass Flow rate: 300 Kg/hr

                                        Pressure: 250 bar

                   Thermodynamic properties of Gas at 250 bar and 21oC

                              Density (ρ): 192.46225841658 Kg/m3

                          Viscosity (µ): 2.38456076692404*10-5 N.s/m2

                             Compressibility (Z): 0.852039803268427

                          Kinematic Viscosity (ν): 1.23897578*10-7m2/s

                              Volumetric Flow Rate: 1.558747m3/hr

                   Volumetric Flow Rate (Q): 4.32985278*10-4m3/s

      Tubing data:                3/4" Tubing           1” Tubing          5/4” Tubing
 Outer Diameter (O.D.)               1.9cm                  2.54cm           3.175cm
Thickness* (from Table 1)           0.095”                   0.12”            0.156”
  Internal Diameter (D)           0.014174m             0.019304m           0.023825m
 Roughness (k) (Table 2)           0.00008m             0.00008m            0.00008m
 Roughness Factor(k/D)              0.00564                 0.00414          0.00335
   Velocity of Gas (v)          2.74409026 m/s       1.47941028 m/s      0.971219582 m/s
 Reynold’s Number (Nre)         3.13837927*105       2.30501165*105      1.86761573*105
Coefficient of Friction(λ)           0.032                   0.029            0.028
          (Fig)
  Length of Tubing (L)               10 m                    10 m             10 m
 Pressure loss (ΔP) using        16364.1139 Pa        3164.05144 Pa       1067.13748 Pa
        Formulae
   Pressure Loss (ΔP)          0.16364.1139 bar     0.0316405144 bar     0.0106713748 bar



                                                                                            37
Table for Tubing Data (Parker Hannifin Corp.)




                            Table 2: Maximum Allowable Working Pressure for Tubing




*Thickness of tubing required to handle Maximum allowable Working Pressure assumed
to be the next higher available value of pressure above 300bar




                                                                                     38
Roughness of Materials

   Aluminium, drawn/pressed                      New                  0.0013 - 0.0015 mm

   Aluminium, drawn/pressed                      Used                    to 0.03 mm

     Brass, drawn/pressed                        New                  0.0013 - 0.0014 mm

     Brass, drawn/pressed                        Used                    to 0.03 mm

           Cast iron                     average city severage             1.2 mm

           Cast iron                           Incrusted                  to 3.0 mm

           Cast iron                       new, bituminized             0.10 - 0.13 mm

           Cast iron                        new, with skin               0.2 - 0.6 mm

           Cast iron               operating several years, cleaned        1.5 mm

           Cast iron                         slightly rusty              1.0 - 1.5 mm

    Copper, drawn/pressed                        New                  0.0013 - 0.0015 mm

    Copper, drawn/pressed                        Used                    to 0.03 mm

     Glass, drawn/pressed                        New                  0.0013 - 0.0015 mm

     Glass, drawn/pressed                        Used                    to 0.03 mm

             Steel                   after long operation cleaned       0.15 - 0.20 mm

             Steel                   homogeneous corrosion pits            0.15 mm

             Steel                        intensely incrusted            2.0 - 4.0 mm

             Steel                    slightly rusty and incrusted      0.15 - 0.40 mm

   Steel, longitudinal welded              new, bituminized             0.01 - 0.05 mm

   Steel, longitudinal welded              new, galvanized                0.008 mm

   Steel, longitudinal welded              new, rolling skin            0.04 - 0.1 mm

        Steel, weldless              new, comm.size galvanized          0.10 - 0.16 mm

        Steel, weldless                 new, neatly galvanized          0.07 - 0.10 mm

        Steel, weldless                      new, pickled               0.03 - 0.04 mm

        Steel, weldless                    new, rolling skin            0.02 - 0.06 mm

        Steel, weldless                     new, unpickled              0.03 - 0.06 mm
                                Table 3 Roughness of Materials




                                                                                           39
Grades of Steel Used:

   The Society of Automotive Engineers (SAE) designates SAE steel grades. These are four
digit numbers which represent chemical composition standards for steel specifications.
The American Iron and Steel Institute (AISI) originally started a very similar system. Over time
they used the same numbers to refer to the same alloy, but the AISI system used a letter prefix to
denote the steelmaking process.

Carbon and alloy steel
       Carbon steels and alloy steels are designated by a four digit number, where the first digit
indicates the main alloying element(s), the second digit indicates the secondary alloying
element(s), and the last two digits indicate the amount of carbon, in hundredths of a percent by
weight. For example, a 1060steel is a plain-carbon steel containing 0.60 wt% C.



Major classifications of Steel


 SAE designation                        Type
       1xxx                         Carbon steels
       2xxx                         Nickel steels
       3xxx                    Nickel-chromium steels
       4xxx                       Molybdenum steels
       5xxx                        Chromium steels
       6xxx                  Chromium-vanadium steels
       7xxx                        Tungsten steels
       8xxx               Nickel-chromium-vanadium steels
       9xxx                   Silicon-manganese steels
SAE designation                         Type
                        Carbon steels
      10xx                Plain carbon (Mn 1.00% max)
      11xx                         Resulphurized
      12xx              Resulphurized and Rephosphorized
      15xx              Plain carbon (Mn 1.00% to 1.65%)



                                                                                                     40
Manganese steels
     13xx                         Mn 1.75%
                       Nickel steels
     23xx                         Ni 3.50%
     25xx                         Ni 5.00%
                  Nickel-chromium steels
     31xx               Ni 1.25%, Cr 0.65% or 0.80%
     32xx                    Ni 1.25%, Cr 1.07%
     33xx               Ni 3.50%, Cr 1.50% or 1.57%

     34xx                    Ni 3.00%, Cr 0.77%

            Nickel-chromium-molybdenum steels
     43xx              Cr 0.50-0.95%, Mo 0.12-0.30%
     47xx            Ni 1.82%, Cr 0.50-0.80%, Mo 0.25%
                       Ni 1.82%, Cr 0.50%, Mo 0.12%
     81xx
                               V 0.03% min
    81Bxx              Ni 1.05%, Cr 0.45%, Mo 0.20%
     86xx              Ni 0.30%, Cr 0.40%, Mo 0.12%
     87xx              Ni 0.30%, Cr 0.45%, Mo 0.12%
     88xx              Ni 0.55%, Cr 0.50%, Mo 0.20%
     93xx              Ni 0.55%, Cr 0.50%, Mo 0.25%
     94xx              Ni 0.55%, Cr 0.50%, Mo 0.35%
     97xx              Ni 3.25%, Cr 1.20%, Mo 0.12%
     98xx              Ni 0.45%, Cr 0.40%, Mo 0.12%
   Nickel
                       Ni 0.55%, Cr 0.20%, Mo 0.20%
 molybdenum
     46xx              Ni 1.00%, Cr 0.80%, Mo 0.25%
Chromium steels    Ni 0.85% or 1.82%, Mo 0.20% or 0.25%
     50xx                   Ni 3.50%, Mo 0.25%
    50Bxx           Cr 0.27% or 0.40% or 0.50% or 0.65%
     51xx                  Cr 0.50%, C 1.00% min
    51xxx                    Cr 0.28% or 0.50%
    51Bxx          Cr 0.80%, 0.87%, 0.92%, 1.00%, 1.05%
    52xxx                  Cr 1.02%, C 1.00% min


                                                          41
Stainless Steel SS316—


       The second most common grade (after SS304); for food and surgical stainless steel uses;
alloy addition of molybdenum prevents specific forms of corrosion. It is also known as marine
grade stainless steel due to its increased resistance to chloride corrosion compared to type SS304.
SS316 is often used for building nuclear reprocessing plants. SS316L is an extra low carbon
grade of SS316, generally used in stainless steel watches and marine applications, as well
exclusively in the fabrication of reactor pressure vessels for boiling water reactors, due to its high
resistance to corrosion. Also referred to as "A4" in accordance with ISO 3506, SS316Ti includes
titanium for heat resistance, therefore it is used in flexible chimney liners.




                                                                                                         42
An example of how the Cascade System Utilizes a Three Stage Storage
  Bank to Provide a More Efficient System than the Single Control Volume
                                  Storage Supply


      An article published by RP publishing written by Ralph O. Dowling of C.P.
Industries is summarized in this section to better describe the cascade system. The
cascade system as mentioned earlier is a more efficient system than the single
control volume storage supply. A brief description of how the cascade operates will
be described in the following paragraphs. An understanding of the effects of
compression on natural gas is the first step in understanding the cascade system.




                                                                                      43
Table 4: Pressure - scm Natural Gas filled per Unit Volume

Table 3 illustrates how Natural Gas is affected when compressed into the same volume as occupied by 1m 3 of water. It
gives the amount of natural Gas in standard cubic metres(scm) that would occupy 1m3 Volume at a given pressure.




                                                                                                                   44
Storage System for Fast Fill: CASCADE


       A cascade system is comprised of three banks (low, medium, high), which are
high pressure storage vessels. The whole cascade system holds about 891.96 scm of
Natural Gas at 250bar. These are deployed in two different configurations: 40 cylinder
of 75 Ltr capacity and 50 cylinders of 60 Ltr capacity.
       Considering 40 X 75 liter configuration, each of the vessels has a water volume
of 0.075 m3, which would be 3 m3 total water volume. Banking cascade storage vessels
have a design pressure of 275 bar and a storage pressure of 250 bar. At 250 bar
each storage vessel will contain 22.299 scm of natural gas (0.075 m3* 297.32 scm / m3
water = 22.299 scm) at 210C. From Table3, at 250 bar, the volume of Natural Gas is
297.32 scm / m3 water. The Total Natural Gas contained in the system if all three
stages are at 250 bar and 21oC would be 891.96 scm (22.299 * 40).


The following assumptions have been made for the cascade sequence explanation:


Manual cascade system
   1. Temperature remains constant
   2. Each vehicle cylinder has a water volume of 65liters (0.065 m3)
   3. The vehicle cylinder will contain 16.40 scm of natural gas at a pressure of
       200bar
   4. Each vehicle cylinder(s) is initially empty
   5. No replenishment of the cascade bank during the refueling cycle


       The liquid volume (empty) of the vehicle cylinders can be calculated by dividing
the specified capacity at 200bar (16.40 scm) by the amount of gas in scm (from Table 3)
contained in 1m3 liquid volume at 200bar. So the total water volume of the vehicle
cylinder would be 16.40 scm / (252.33 scm / m3) = 0.065 m3




                                                                                          45
Cascade as a Single Control Volume

      The Cascade is first taken to be a single control Volume of 40 cylinders of 75
liter Water Capacity each. Total Capacity is 3000 (75*40) Water Liters at 250 bar.
The Available quantity of Natural Gas to be dispensed at 200 bar would be the
difference of scm of Natural gas held in the Cascade at 250 bar and at 200 bar from
Table3.


             Amount of Natural Gas per m3 water at 250 bar: 297.32 scm
             Amount of Natural Gas per m3 water at 200 bar: 252.33 scm
                          Water Capacity of cascade: 3m3
      Available Qty of Natural Gas to dispense: (297.32-252.33)*3 = 134.97 scm
              Number of Vehicle cylinders filled: (134.97/16.40) = 8.229


      Therefore approximately Eight (8) vehicle cylinders can be completely filled at
200 bar from a 3000 water liter cascade at 250 bar without the compressor having to
recharge the cascade.




                                                                                        46
Cascade as a Banking System



       The Cascade is now divided into separate Banks (Low-med-High) based on the
priority with which they fill the vehicle cylinder. The Ideal configuration is 50% of all
cylinders be deployed for Low Bank, 30% Medium bank, 20% High Bank


                               Out of 40 cylinders in the Cascade
                                     Low bank cylinders: 25
                                   Medium bank cylinders: 10
                                     High Bank cylinders: 5


       Now, assume that the First NGV is ready to be serviced. The first vehicle can be
completely filled from the low storage bank without having to switch to the next storage
bank. The low bank contains 557.475 (=22.299*25) scm of natural gas at 250 bar, after
the first vehicle is serviced, the low bank will contain 541.075 scm (557.475 – 16.40) of
natural gas at (541.075/1.875) = 288.573 scm / m3
       From Table 3 interpolate 288.573 scm / m3 to find the pressure in low storage
bank after the first NGV has been filled (239.57 bar).



       The Second vehicle is now ready for service. The next vehicle can also be filled
to the 200 bar level from the low bank. The medium bank will not have to be used yet.
The second vehicle will be filled from the low bank until the pressure in the low bank
and the NGV pressures equalize. The same mathematical process for the first NGV
example must be done for the second.
       524.675 scm (541.075 -16.40) of Natural gas remains in Low Bank at
(524.675/1.875) 279.82 scm / m3. From Table3 interpolate 279.82 scm / m3 to find the
pressure in the low storage bank (229.24 bar).




                                                                                            47
After the Third vehicle is serviced, 508.275 scm (524.675-16.40) of Natural Gas
remains in Low Bank at (508.275/1.875) 271.08 scm / m3, which corresponds to
(218.90 bar) pressure.


      After the Fourth vehicle is serviced, 491.875 scm (508.275-16.40) of Natural
Gas remains in Low Bank at (491.875/1.875) 262.33 scm / m3, which corresponds to
(210.28 bar) pressure.


      After the Fifth vehicle is serviced,475.475 scm (491.875-16.40) of Natural Gas
remains in Low Bank at (475.475/1.875) 253.58 scm / m3, which corresponds to
(201.67 bar) pressure.


      The Sixth vehicle cannot be filled to the 200 bar level from the low bank. The
medium bank will now have to be used to top off the vehicle. The sixth vehicle will
initially be filled from the low bank until the pressure in the low bank and the NGV
pressures equalize. For that, we find the equalization pressure of the Low Bank with the
NGV cylinder, which is the pressure corresponding to
(Available quantity of gas) / (Volume of Low Bank + Volume of NGV cylinder)
      = 475.475 / (1.875+0.065) scm gas/m3
      = 245.09 scm gas/m3, which from Table3 corresponds to 193.05 bar pressure.


      Since the low storage bank and the NGV are equalized, the NGV cylinder(s) now
contain a pressure of 193.05 bar (< 200 bar), the NGV must be topped off by the
medium storage bank to achieve the desired 200 bar fill level. The low bank now
contains 459.543 scm (245.09 scm/m3 * 1.875m3) of natural gas. The vehicle now
contains 15.93 scm of natural gas (0.065m3 * 245.09 scm / m3)


      The medium storage bank must provide 0.47 scm (16.40 scm – 15.93 scm) of
natural gas to top off NGV number 6.
      The Medium Bank contains 222.99 scm (22.299*10) of Natural Gas. The same
mathematical process as before must be compiled to determine the remaining pressure.



                                                                                           48
(222.99-0.47) / 0.75 m3 = 296.693 scm / m3
Using Table3, interpolate 296.693 scm / m3 to determine the total pressure remaining in
the Medium storage Bank (248.21 bar).
      This method of calculating total volume and total pressure remaining can be
applied to fill process from a cascade system for Sixteen (16) NGVs. The first Sixteen
vehicles can be filled from the Low and Medium storage banks only with the Low
storing bank containing (326.85 scm at 136.16 bar) and the Medium storage bank
containing (191.150 scm at 201.67 bar) after the Sixteenth NGV has been filled.


      NGV number 17 will have to be filled from the low, medium, and high storage
banks. The Seventeenth vehicle will first equalize pressure with Low storage bank
(132.71 bar) 326.85 scm / (1.875 + 0.065) m3 = 168.479 scm / m3
      Through interpolation using Table3 the equalization pressure would be
132.71 bar.
After an initial fill from the Low storage bank, 10.95 scm of natural gas would be
contained in the NGV cylinder (0.065 m3 * 168.479 scm / m3).
      NGV number 17 will now equalize pressure with the Medium storage bank
(196.50 bar). With 191.150 scm remaining in the Medium storage bank, the pressure in
the Medium storage bank and the NGV cylinder will equalize pressures.
(191.50 + 10.95) scm / (0.75 + 0.065) m3 = 247.97 scm / m3


      Through interpolation using Table3 the equalization pressure would be
196.50 bar.
After the Low and Medium storage banks have gone through the equalization process,
the High storage bank must be utilized to top off the vehicle. NGV number 17 now
contains 16.11 scm (0.065 m3 * 247.97 scm / m3) of natural gas. With the NGV
containing 16.11 scm of natural gas, 0.29 scm (16.40 scm – 16.11 scm) must be added
to achieve the full fill level for NGV number 17. The high bank has a capacity of
111.495 scm (22.299*5) of Natural Gas. The remaining natural gas in the high bank
would be 111.205 scm (111.495 scm – 0.29 scm) at a pressure of 248.21 bar.
111.205 scm / 0.375 m3 = 296.54 scm / m3



                                                                                          49
Through interpolation, using Table3, the pressure remaining in the third storage
bank would be 248.21 bar.


      If this process is continued, 25 NGVs can be filled before this cascade system
will need to be recharged by the compressor. If a single control volume storage
system were used instead of cascading, only 8 vehicles could be recharged before the
system would have to be replenished by the compressor. The Following Table
compares the efficiencies of the two systems.




                     Number of        Natual gas      Natural gas         Efficiency of
                       vehicles       capacity of   capacity (scm) of    system = (# of
                     that can be      each NGV        system when        vehicles * NG
    System              fueled          (scm)             fully         capacity of each
                  by the particular                     charged           NGV) / NG
                        system                                           capacity of the
                                                                             system


   Cascade               25             16.40            891.96            45.96%

Single Control           8              16.40            891.96            14.71%
   Volume




                                                                                           50
Suggestions for better safety and services


  1. PNG
       a. It is suggested to have Fuming Strips (perforated strips with smelling
           agent) of mercaptin (Ethyl or methyl) to be supplied annually along with
           the Gas consumption bill along with an instruction sheet which asks the
           consumer to make each family member sniff the Strip and have an idea
           about the smell which indicates them the presence of any form of leakage
           in the supply system or flow meter. This would enable the consumer to be
           able to detect / prevent a major Hazard.
  2. CNG
       a. I have strongly felt the need for the existence of regular Awareness
           Camps at filling stations where consumers get to witness the immediate
           remedial steps needed to be taken in case of an emergency within the car.
               i. There should be Fuming Strips which replicate the smell of gas
                 leakage at the concentration at which it exists in the car.
              ii. The camp should display protocols to be followed step by step in
                 case of an emergency’ depicting various complications which may
                 arise and ways to counteract them.
             iii. The camp also shows the dangerously high pressures that exist in
                 various tubings within the car and how lethal such high pressures
                 can be. Citing common examples of the muzzle pressure inside an
                 AK47 making the audience experience a gauge pressure of 1bar on
                 their hands and explaining how dangerous a 200bar pressure
                 stream can be. Consumers also need to be repeatedly told about
                 common characteristic properties of the Natural Gas.
       b. Every filling attendant must be given the authority to issue non-compliance
           papers to CNG vehicles. Where any vehicle found to have dangerous /
           worn out nozzle receivers(female) would be advised to get it changed
           within a stipulated time period (suggested:1 Month). Failing which, CNG



                                                                                        51
will not be dispensed to the vehicle. This is in direct accordance towards
         the safety of the filling attendants as dangerous recoils and snake sliding
         in the hose occurs due to ineffective contact between the O-rings and the
         female nozzle walls. The current inspection of cylinders at 5 years and
         tubing at 1 year does not take into consideration normal daily wear and
         faults which need immediate attention. The attendants have been
         entrusted with such responsibilities as they witness hands-on the exact
         state and seriousness of the issue.
3. CNG Filling Stations
      a. UTILISING VENT GAS
             i. Vent gas which is released into the atmosphere in order to break
                the gas flow path in the dispenser nozzle so that it can be
                disconnected from the vehicle should be utilized. A few suggested
                uses of the gases (need of further experimentation required):
                   1. Producing electricity (the gas at approx 200bar can be
                      effectively used to produce energy by expansion over a
                      turbine and later combusted to produce a considerable
                      amount of energy to power the Flood lights on a filling
                      station.
                   2. The gas can be collected over an overhead container where
                      all the dispensers release their vent gas and this gas can be
                      later combusted to produce energy to power the
                      infrastructure around a CNG Filling station.
                   3. Implementation of SCADA, in order to effectively monitor
                      various units under a control room at once and result in swift
                      delivery of services and prompt servicing.
                   4. Quick licensing of compressor packages in order to result in
                      less effective kilometer usage on transport of LCV’s and
                      ease in meeting rising gas demands. (eg: licensing of
                      compressor package at Dwarka sec-20 filling station would
                      result in a net saving of 10 Km per LCV filling trip)



                                                                                       52
References




    D. Rood, ”A practical guide to care, maintenance and troubleshooting of capillary
    Gas Chromatographic systems“, 2nd edition, Hüthig Verlag, Heidelberg, 1995

    Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003). Materials and
    Processes in manufacturing (9th edition.). Wiley.

    Jeffus, Larry F. (2002). Welding: Principles and Applications. Cengage Learning.

    Dowling, Ralph O., .Cascade Basics, RP Publishing, 1993.

    Moran, Michael J., Shapiro, Howard N., .Fundamentals of Engineering
    Thermodynamics., John Wiley and Sons Inc., New York, pp. 488-449, 1999.

    Tubing manual and selection Guide, Product Catalogue: Parker Hannifinn
    Corporation, 2007

    Ronald A. Hites Mass Spectrometry Gas Chromatography

    National electric code (NEC), National Fire protection Association (NFPA),
    Batterymarch Park, Quincy, MA




                                                                                        53

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CNG Filling Operations Project Report Summary

  • 1. 0
  • 2. Project Report on CNG filling Operations Ankur Rawal 1
  • 3. CERTIFICATE Certified that this project report “CNG filling Operations” at Indraprastha Gas Limited is the work of “Ankur Rawal” who carried out the project work under the Operations & Maintenance department. Mr. Amit Kumar Deb Manager (CNG - O&M) Mr. Ujwal Bhandari General Manager (CNG-O&M) Mr. P.K. Pandey Chief General Manager (CNG-O&M) Mr. Manjeet Singh Vice President (E&P) 2
  • 4. ABSTRACT Filling operations of Compressed Natural Gas (CNG) in Natural Gas Vehicles Natural gas is being used as an alternative fuel to gasoline. Natural Gas vehicle (NGV) refueling stations incorporate a series of processes which make the gas dispensable. The report focuses on understanding various aspects of these processes and test and suggest changes in their functioning. Various tests and observations were made on the compressor and inlet pipes and pressure drops calculated. Useful characteristics of CNG during the fill process are temperature, pressure, and flow rate, as well as, total volume dispensed. CNG is dispensed to an NGV through a process known as the fast fill process, since it is completed in less than five minutes. The system is being constantly upgraded in order to result in lower filling time and make it comparable to that of petrol or diesel fillings. The report also highlights the quality control operations at Indraprastha Gas Limited (IGL). The Gas Chromatography installation at Mahipalpur Gas Station has been carefully studied along with viscosity relations with dilution were done for snoop solution used to test leakage. 3
  • 5. Acknowledgments I wish to acknowledge all the people who have helped me finish this Report. Without the generosity of others there is no way that I could have finished it. The report is an outcome of the advice and tutelage of several people who work at Indraprastha Gas Limited (IGL). I would like to thank my advisor and mentor Mr. Ujwal Bhandari (General Manager CNG-O&M), first of all, for being so patient with me and being an excellent mentor throughout my time in IGL. Without the advice and knowledge of Mr. Bhandari, the completion of this document would have been impossible. The other guides of my endeavor, Mr. Amit Kumar Deb (Manager CNG-O&M Jail Road Control Room) and Mr. Abhinav Sahay (Additional Manager CNG-O&M Lado Sarai Control Room) have also been very helpful for advice and knowledge of subjects contained in this report. The entire team of Engineers and Technicians at Jail Road and Lado Sarai Control Rooms have in some way or the other helped me understand practical aspects of whatever I had learnt in texts earlier. I am highly indebted to Mr. Manjeet Singh (Vice President – E&P) for he believed in my objectives of undergoing this internship and made an exception in allowing me to be a part of the organization after completing the second year of my four year graduation in Chemical Engineering. My college, USCT has been very supportive as well, to have allowed me to use their facilities and equipments for a few tests. University Professors such as Dr. Biswajit Sarkar have helped me with the required textbooks and constantly answered all my queries regarding fluid dynamics and Heat Exchangers. Thanks and Regards, 4
  • 6. AN OVERVIEV OF INDRAPRASTHA GAS LIMITED COMPANY PROFILE Indraprastha Gas Limited (IGL), a Joint Venture of GAIL (India) limited and BPCL along with the government of NCT of Delhi was incorporated on December 23, 1998 to implement the compressed Natural gas (CNG) expansion program and the Piped Natural Gas (PNG) project for varied application in the domestic and the commercial sector. In 1999, IGL took over the Delhi City Gas distribution Project started by GAIL (India) Ltd. which focused on supply and distribution of CNG & PNG in the capital city. Thereafter IGL worked tirelessly to take the project to new heights. IGL’S VISION -‘To be the leading clean energy solution provider, committed to stakeholder value enhancement, through operational excellence and customer satisfaction’ This vision statement signifies five major attributes of the organization. Commitment to the environment Providing complete energy solution and thereby going beyond CNG for transport and PNG for cooking application Enhancing value for beneficiaries including customers, stakeholders and employees Achieving excellence in operations Providing satisfaction to customer 5
  • 7. CNG-Compressed Natural Gas Natural Gas is a combination of Methane, Propane and Butane. Conventional Natural Gas exists above crude oil deposits, and is often wasted or burned in the oil collection process due to the high costs of capturing and using it. When the gas is burned, it prevents the Methane from reaching the atmosphere. Carbon Dioxide into the atmosphere is less harmful than Methane. Natural Gas produces less air pollution than any other fossil fuel. Use of CNG vehicles can reduce Carbon Monoxide emissions as much as 93% Nitrogen Oxide reduces about 33% and Hydrocarbons are reduced by about 50%. Natural Gas emits almost no carcinogenic particulates. By using CNG to power vehicles a bi-fuel tank can exist; therefore, in locations without CNG pumps, Petrol may be used by just flipping a switch. Since CNG is a clean-burning fuel, maintenance costs are lowered. CNG is 130 octanes, which is considerably higher than 93 octanes for Petrol; consequently, the CNG vehicle is more energy efficient. Besides using Natural Gas to power vehicles, it can also create electricity and heat homes and commercial buildings. Compressed Natural Gas (CNG) is natural gas that has been compressed for storage aboard a natural gas vehicle (NGV), a vehicle whose engine is fueled by Natural Gas. Natural gas is compressed to high pressure (200 bar/20.7 MPa or higher) to most effectively utilize the NGV’s limited available space for storage. ADVANTAGES DISADVANTAGES Abundant Supplies Nonrenewable Resource Low Emission Vehicles Decreased Range Advanced Vehicle Developments New Refueling Sites Required Reduced engine maintenance Expensive Engine Modifications Inexpensive 6
  • 8. It is proven manifold that natural gas is a very clean fuel. The world Energy Conference of Tokyo 1996 announced that natural gas is the No.1 alternative because: 1. Natural gas has excellent combustion properties, 2. Natural gas is a safe fuel (lighter than air, high ignition temperature), 3. Natural gas is a clean fuel (no sulphur, no lead, no particles, little NOx, CO and HC). 4. Natural gas has abundant reserves, wide spread over the globe. 5. Natural gas is a strategic fuel, 6. Natural gas is cheap if we exclude taxes. Natural Gas Vehicle (NGV) Basics Natural gas used in vehicles is no different than natural gas used in residential or commercial markets, except that it is compressed to high pressures for storage purposes. Compressed natural gas (CNG) is gas compressed to pressure generally ranging from 200 to 259 bar (20.7Mpa to 25Mpa). At the dispenser, Natural Gas is delivered into vehicles either by weight (in kilograms) or by Gasoline liter equivalents (GLE – an energy equivalent comparison to gasoline) and carries an octane rating between 122 and 130. There are many types of natural gas vehicles (NGV’s), including dedicated, Bifuel and dual fuel models. There are distinguished by whether the engine runs only on natural gas (dedicated), operates on either natural gas or gasoline (Bifuel), or simultaneously burns a combination of both liquid fuel (such as Diesel or Petrol) and natural gas (dual fuel). CNG is stored onboard a vehicle in several types of pressurized vessels that conform to industry-recognized standards for installation (the NGV 2 standard in Canada & USA or OISD Standard 226 for City Gas distribution in India) If NGV’s and equipment are in sound condition, you can expect them to perform reliably when they are well maintained by a trained technician and drivers are well informed and trained. 7
  • 9. Although conventional wisdom holds that natural gas engines should require fewer oil changes and perhaps even less frequent scheduled maintenance because of less carbon build-up, regular maintenance of the vehicle, engine and/or conversion system will ensure the superior performance of the NGV versus its gasoline and diesel counterparts. A CNG fueling facility typically consists of a compressor, storage Cascades and a dispenser system. Dispensers come in two types: fast fill, which delivers fuel at a rate comparable to gasoline or diesel systems, and time fill, which fuels vehicles over a period of time. The actual fueling of an NGV is similar to fueling with gasoline or diesel. CNG Quality Control An extensive quality control of the incoming Natural Gas for Refueling in the city of New Delhi is done at the Mahipalpur CNG Station, which comes under the Lado Sarai Control Room. A Gas Chromatograph monitors and records the quality of the Natural Gas at all hours of the day all round the year. It measures quantitatively the %composition of various components of the Natural Gas, which further helps in maintaining exact desirable proportions. The incoming Gas from GAIL is odorless and therefore, a smelling agent (Ethyl Mercaptin and Methyl Mercaptin) is mixed into the Gas at IGL’s Patparganj Plant. Where the smelling agent is introduced at traceable quantities as the concentration magnifies when compressed. A detailed functioning of the Gas Chromatograph is explained further. Major contents of the Quality control are: %Composition of C 1 - C6& above, Gross Calorific Value, Net Calorific Value and specific volume. As the Gas upon combustion releases water in the form of vapor, this water vapor releases more heat in the process of condensation. This heat when added to the Gross Calorific value (GCV) of the fuel is known as the Net Calorific Value (NCV). Specific Volume is the volume of Gas occupied by 1 Kg of Gas at Standard Temperature and Pressure (STP). 8
  • 10. Gas Chromatograph (GC) In a Gas Chromatogram (GC) Analysis, 0.1-10µL (micro liter) of a mixture of compounds is injected into a heated Injector, where all of the compounds vaporize. A gentle stream of the Carrier Gas, Helium (He) moves the entire mixture onto the Collumn, the corresponds of the mixture separate as they pass through the column. The process can be considered as an exceptionally good Fractional distillation using a superb fractionating column. Figure 1: Schematic representation of the components of a GC The Process The separated compounds pass from the column into a detector that produces an electrical signal proportional to the amount of compound passing through the detector. A recorder provides a graph. The Gas Chromatogram is plotted against the detector Signal versus Retention time. The Gas chromatogram shows a peak for each compound in the mixture. The retention time can be measured from the Chromatogram. An Integrator measures the areas under the peaks in the Gas Chromatogram. 9
  • 11. Thermal Conductivity Detector (TCD) Flame Ionization Detector (FID) Figure 2 detectors used in Gas Chromatography The Chromatogram A chromatogram consists of a base line and a number of peaks. The area of a peak allows quantitative determinations. Starting point of a chromatogram is the time of injection of a dissolved sample. The time interval between a peak and the point of injection is called retention time tR. A component can be identified by its retention time (qualitative determination). The retention time is the sum of the residence time of a solute in the mobile phase (t 0) and in the stationary phase (t R' = net retention time); t 0 is also known as dead time. It is the time required by a component to migrate through the chromatographic system without any interaction with the stationary phase (also called air or gas peak). For a given, the area under its peak on the chromatogram is proportional to the amount of the compound in the sample. Direct comparison of peak areas for different compounds is unreliable because detectors do not have the same sensitivity to all compounds. For this reason, a sample of the Natural Gas is maintained in the GC. The Area under the chromatogram is then compared to that of the sample, and the result is recorded. 10
  • 12. Figure 4: Schematic Chromatogram COMPONENTS Jan Feb Mar Apr May Jun July C1 92.7464 92.4233 94.102 91.7059 90.8413 88.64 91.4763 C2 4.0807 4.2759 4.6296 4.3309 4.4206 5.2094 4.3462 C3 0.8629 1.0646 0.7279 0.8726 0.6122 1.3443 0.7145 I-C4 0.1161 0.1541 0.1227 0.0991 0.0232 0.1589 0.058 N-C4 0.1641 0.2225 0.1657 0.1368 0.0003 0.1705 0.0626 N2 0.1745 0.2326 0.1659 0.1904 0.1045 0.0983 0.1364 CO2 1.8521 1.627 0.0793 2.6596 4.0063 4.2942 3.2024 Neo-C5 0 0 0 0 0 0 I-C5 0.0029 0 0.0053 0.0037 0.0008 0.0297 0.0023 N-C5 0 0 0.0015 0.001 0.0007 0.0256 0.0013 C6+ 0.0003 0.0001 0 0 0 0.0291 0 GCV 9294.51 9368.78 9476.66 9230.251 9043.145 9257.759 9142.276 SG 0.6059 0.6082 0.5903 0.6145 0.6219 0.6419 0.6164 Table 1: GC data Mahipalpur Plant (Period: Jan-July2011) 11
  • 13. C1: Methane C2: Ethane C3: Propane I-C4: Iso-Butane N-C4: Normal Butane N2: DiNitrogen CO2: Carbon Dioxide Neo-C5: Neo Pentane I-C5: Iso Pentane N-C5: Normal Pentane C6+: Higher Alkanes GCV: Gross Calorific Value (J/mol) SG: Specific Gravity (m3/Kg) Standard Reaction of HC combustion: ………………….…ΔHr = Gross Calorific Value Limitations: Only compounds with vapor pressures exceeding about 10–10 torr can be analyzed by gas chromatography mass spectrometry (GC-MS). Many compounds with lower pressures can be analyzed if they are chemically obtained (for example, as trimethylsilyl ethers). Determining positional substitution on aromatic rings is often difficult. Certain isomeric compounds cannot be distinguished by mass spectrometry (for example, naphthalene versus azulene), but they can often be separated chromatographically. Accuracy: Qualitative accuracy is restricted by the general limitations cited above. Quantitative accuracy is controlled by the overall analytical method calibration. Using isotopic internal standards, accuracy of ±20% relative standard deviation is typical. 12
  • 14. Difference between Gross Calorific Value and Net Calorific Value: The Water produced in the combustion reaction is in the gaseous state. This water when condensed to liquid state at ambient temperatures in the cylinder releases the Latent heat of Condensation which unlike the Gross Calorific Value is released from the exhaust when it interacts with air at ambient temperature. This additional energy is not used for the expansive working within the piston cylinder and therefore is not accounted for in the actual Calorific Value of the gas mixture. The Net Calorific Value is what we read in instruments and we subtract the known value of Latent heat of condensation of steam at given conditions to obtain the Gross Calorific Value. Net Calorific Value (NCV) – Latent heat (condensation) = Gross Calorific Value (GCV) CNG Refueling Station A CNG station is a site consisting of interconnected equipment, which is designed to compress Natural Gas to a high pressure and either store the CNG (if the site is equipped with storage) or dispense it directly to a natural gas vehicle for refueling. A CNG station typically consists of one or more compressor packages to compress the Natural Gas, and several additional systems, which include Cascade storage systems, PLC based controls system such as a priority controller panel, a temperature/pressure compensation panel, a buffer panel, gas dryers, fast refueling (CAR dispensers) and time refueling (BUS) dispensing units. The Station includes separate areas for Compression, Storage and Dispensing. It includes Air compressor pipes, Water pipelines etc. It also includes provisions for safety against Fire or Leakage. The provisions include Carbon dioxide (CO2) Cylinders; Dry Chemical Powder (DCP) cylinders etc. 13
  • 15. CNG Distribution Network Main line ~18-20 bar ~18-20 bar CNG ~250 bar CNG Compressor Compressor Mobile Mobile ~18-20 bar ~250 bar Cascade Cascade Storage Storage MOTHER Cascade Cascade ON-LINE STATION ~200 bar STATION Dispenser Dispenser ~200 bar ~200 bar CNG Vehicle Mobile Mobile CNG Vehicle Cascade Cascade Booster ~200 bar DAUGHTER Compressor DAUGHTER BOOSTER STATION STATION Dispenser Dispenser ~200 bar CNG Vehicle CNG Vehicle Figure 5: Schematic diagram of CNG distribution at IGL Type of stations at IGL Mother station: It’s a station where a direct gas line received and SCM capacity of compressors installed there is more than 1200 SCM and LCV is also filled. Online station: It’s a station where online gas line is received from GAIL but the capacity is up to or below 1200 SCM. Cascades filling are also there. Daughter booster station: It’s a station where compressors are not installed and gas is being compressed by means of a device named booster. Daughter station: It’s a station where gas is not compressed at the station itself and is filled direct from the LCV. 14
  • 16. CNG Station Basics Key CNG Refueling Station Equipment: Gas Dryer (inlet or outlet) Compressor Package System (bare shaft compressor, inter-stage cooler, piping, separators) - Driver (electric motor or gas engine) - Low pressure inlet train - High pressure outlet system - Canopy or housing (weather protection/noise attenuation) Cascade Storage System Priority Control Panel Car Dispenser Dispenser (single or double hose, metering or non-metering, trickle, fast fill) Compression System Natural gas is usually transported to the CNG station site from the main Gas Pipeline provided by GAS AUTHORITY OF INDIA LIMITED (GAIL). This gas can range in pressure from as low as 12 bar (gauge pressure above atmospheric), to as high as 35 bar/ 3.45 Mpa or higher. In any case, it is still too low of a pressure for use in vehicle storage systems. For this reason, the gas must be compressed. However, prior to compressing the gas, the incoming gas may need to be conditioned further, so as not to damage the compression equipment or downstream systems. For example, if the gas is “wet”(has an unusually high concentration of evaporated water), then the gas will first pass through a dryer, if the Sulphur contents in the gas is higher, it also should be removed. This is a large vessel, surrounded by related components, which removes water from the gas stream using a “desiccant” material. 15
  • 17. Once the gas is properly conditioned as required, it then enters the compressor. The compressor is typically the largest and most complex piece of equipment in the entire refueling station. It raises the pressure of the natural gas to 250 bar (25Mpa), or higher, using a number of separate stages, which increase the gas pressure in increments. The Compressors are typically reciprocating compressors. These are driven in a rotational manner, with the compressor translating this rotational force into a Piston/Cylinder combination. Much like the reverse of an engine, a compressor uses a series of valves to move the gas into each cylinder, compress it with a Piston, and then discharge in into the next stage at an increased pressure. The cylinder configurations can either be a “W” or “V” shape, or horizontally opposed. Metering Skid The first Equipment on the Main Inlet piping is the Metering Skid. It helps monitor precise Station Inlet GAS characteristics as per requirement up to compressors which helps study gas loses over compression etc. Flow mater readings help CNG Station Marketing and Sales Department tally Station reconciliation with respect to sales and also IGL gas reconciliation with GAIL (India) Pvt. Ltd. Main Functions: Pressure regulation. Gas filtration. Preventing Pilferage Precise metering Cross-Checking of metering Emergency shut-down of station through Main Isolation Valve 16
  • 18. Major Components Suction Line Filter The Suction Line filter includes protection from moisture, inorganic and organic acid resulting from burnout or chemical changes in the system. It also clears away combustible dust, which may be introduced through mechanical work done over the Pipeline. It has a 5µm Filter for such unwanted particles. Slam shut-off valve The Slam shut off valve is used in Metering skid for shut off line in case of emergency when line pressure is above 23 kg/cm2 or below 13kg/cm2. It is a Butterfly Valve which is also called the Main Isolation Valve which may be used to cut-off the whole station from the Main Pipeline. Pressure regulating Valve It regulates the pressure of gas in flow line according to adjustable limit. Mass Flow meter Mass flow meter is used in flow line to continuously monitor the input mass flow of Gas. It uses a Coriolis Type of mechanism for reading Flow rate. Pressure and Temperature transmitter Pressure transmitter and Temperature transmitter is used to sense Pressure and Temperature in line pressure to Flow Boss. A special Differential Pressure meter is installed across the Filter, which indicates amount of choking residue on the filter as the pressure drop across it. A Differential Pressure of 1 bar or above means that the filter requires cleaning. Flow boss (flow computer) Each characteristic data such as inlet pressure, temperature, Mass Flow etc. for the Gas at Inlet is stored in flow boss to log the data in computer. 17
  • 19. F I L T E R Figure 6 Schematic diagram of the metering skid Compressor drive The Compressor can be driven either by an Electric Motor, or by a Natural Gas engine. For an electric motor drive, an electronic device called a starter or soft start applies power to the motor when the compressor is required to turn on. The motor shaft is coupled to the compressor shaft either directly, or by means of a belt drive. Typically, larger compressors are direct-driven. A compressor package also has a great deal of support equipment associated with the package. Mechanically, the compressor requires a lubricating oil supply to lubricate the cylinders, pistons, and other moving parts. It also requires a means to remove from the gas supply oil that is introduced through lubrication. This typically involves a system of filters and separators. Filters are typically placed at the inlet and the discharge of the compressor itself, while in-line gas separators are placed between the stages of compression. Separators spin the gas in a circular motion to use centrifugal force to condense any liquid out of the gas stream. This results in a collection of condensates, typically water and oil, which must be periodically removed from the separator vessels. This is typically done automatically in the packages, with collection in the large recovery tank(s) and later automatically drained into one of the beams in the skid case. 18
  • 20. Compressor: Dresser Rand • Maximum Driver HP 250 (186 kW) • Standard Stroke 7 inch (178 mm) • Crankshaft Diameter 3.75 inch (95 mm) • Cylinder Diameter (LP) 4.00 inches • Cylinder Diameter (HP) 3.25 inches • Main Bearing Length 3.75 inch (95 mm) • Piston Rod Diameter (LP) 1.5 inch (38 mm) • Piston Rod Diameter (HP) 2.25 inch (57.15mm) • Speed 570 (rpm) Materials:- • Frame Cast Iron • Crankshaft Forged Steel • Connecting Rod Forged Steel • Crosshead Aluminum • Main Bearing Aluminum • Crankpin Bearing Aluminum • Pin Bushing Bronze o Crosshead Pin Steel Alloy • Design parameters:- o Suction pressure 14-22 bar o Inter stage compression ratio Suction Discharge  Ist Stage: 3 14-19 bar 45-60 bar  IInd Stage 2 45-60 bar 120-130 bar  IIIrd Stage 2 120-130 bar 220-250 bar • Compressor Flow rate:- 1200 SCMH (916 Kg/Hr) at ideal condition 19
  • 21. Cooling System Compressors generate heat as a natural byproduct of compression. For this reason, they must be cooled. IGL generally has only air-cooled compressors, which means they employ forced air-cooling of the compressor and/or gas stream, instead of water cooling like one would find in a car engine. Some compressor blocks are self-cooling, incorporating a fan onto their main drive shaft, which forces air over the compressor block and over the compressed gas lines. Other blocks require separate heat exchangers, which cool the gas after each stage using a separate fan. These Heat exchangers (Inter Coolers) are Shell and Tube with Fins, with multiple passes in order to result in the desired Temperatures at inlet and outlet for each Stage. Recovery system Another important system is the blow down recovery system. This system, which includes the recovery tanks and various automated valves, captures the gas from the compression system when the machines are shutoff, and maintains a closed loop system by containing and recycling this gas. It also permits the compressor to start and stop “unloaded”, or without compressing gas, by re-circulating the gas within the compressor on start-up, and on shut-down. The majority of this gas is captured in the recovery tanks. The compression equipment also required a great deal of electronic and electrical control, as most skids are automated to a high degree. This means that they must have enough intelligence to turn themselves on, shut themselves off appropriately, and do it all safely, while watching for possible faults. This is generally accomplished by the electronic controls system on–board each skid. The vessel is called a Blow Down Vessel (BDV). A Knock out drum of 900 litres is provided at suction, supply CNG to the compressor through flexible hose to suction collector and first stage cylinder. BDV also acts as a condensate collecting bottle. All the condensate and oil are drained into the BDV. 20
  • 22. Gas Flow within Compressor INTER COOLER INTER COOLER Inlet AFTER COOLER PT102 PT103 PT104 3rd 1st 2nd PCV108 PT101 Stage Stage Stage PRV BDV (Blow PRIORITY Down Vessel) PANEL PT106 Condensate Figure 7: Schematic layout of Compressor system Natural Gas Package Boundary Condenate (Water + oil) 21
  • 23. Mechanism of Compression Expulsion of gas Compression Expansion of residual gas Initial condition Clearance volume Suction stroke Figure 8: PV diagram for Single Stage Reciprocating compressor Shaded area represents net saving in energy Figure 9 PV diagram for Multi Stage Reciprocating compressor 22
  • 24. General Physical Parameters • 1st stage suction pressure (Kg/cm2) = 14.95 • 1st stage discharge pressure (Kg/cm2) = 43 • 2nd stage discharge pressure (Kg/cm2) = 79.49 • 3rd stage discharge pressure (Kg/cm2) = 146 • 1st stage suction temperature (oC) = 37 • 1st stage discharge temperature (oC) = 125 • 2nd stage discharge temperature (oC) = 102 • 3rd stage discharge temperature (oC ) = 96 • Gas temperature after cooler (oC) = 52 • Lube oil pressure (Kg/cm2 ) = 1.02 • Flow meter totalizer reading suction (Kg). • Flow meter totalizer reading discharge (Kg) Compressor start preconditions Tag name Tag description PT-101 1ST Stage suction pressure. PT-102 2nd Stage suction pressure. PT-103 3rd Stage suction pressure PT-104 3rd Stage discharge pressure. PT-105 Engine fuel gas pressure. PT-106 Blow down vessel pressure PT-401 Engine starting air pressure. 23
  • 25. GD-501 Gas detector GD-502 Gas detector FD- 501 Flame detector FD-502 Flame detector TE-101 1st Stage gas suction temperature TE-102 1st Stage gas discharge temperature TE-104 2nd Stage gas discharge temperature TE-106 3rd Stage gas discharge temperature TE202 Engine Jacket Temperature (oC) TE-301 Engine lubes oil temperature TE-108 Engine exhausts gas temperature TE-208 Compressor cooling oil header Temperature LSL-201 CW surge tank level low SSHH-101 Engine over speed contact Emergency stop Emergency stop push button SOV-101 ON Drain solenoid valve ON PT-301 Engine lubes oil pressure PT-302 Compressor lubes system oil Pressure TE-107 Engine inlet manifold temperature 24
  • 26. Priority panel The priority panel consists of a priority valves and non return valves, so arranged that intended use of providing priority to vehicles is achieved. The priority panel is connected to discharge of compressor at one end and is connected in parallel to cascade (storage) and dispenser at other end. If there are no vehicles for gas filling, then priority valve directs the gas flow to cascade. High Bank SOV-110 PT-110 Car cascade Medium Bank SOV-111 PT-111 Car Cascade SOV-112 PT-112 Low bank Car cascade High bank car SOV-113 PT-113 dispenser C N SOV-117 Medium bank G Car Dispenser SOV-118 Medium bank Car Dispenser SOV-112 PT-112 Bus Cascade SOV-112 PT-112 Bus Cascade Mobile SOV-112 PT-112 bank NRV: Non Return valve 25
  • 27. LCV Priority Routing The Mobile Cascade Vehicles, also known as LCV, are Flatbed trucks on which a Cascade has been securely tied. These contain about 2200-2400 Liters of Natural Gas at 250 bar. These are filled at Mother Stations and transported to Various Daughter and Daughter Booster stations under each Control Room. This movement of LCVs around the city has been outsourced to various Transport Contractors, who charge on per-km basis. The Job of priority routing arises in order to minimize the Total number of Kilometers that have to be paid for, while still providing Gas to the Required Daughter and Daughter Booster Stations. Such a Routing is done every time the Contractor revises the Km-Data chart and/or a new Station comes up under a Control Room. This form of Assignment is a Linear Programming Problem (LPP), Transportation Problem. The Following Figures Explain the Priority Routing under Jail Road control room. Figure 10: Suggested Priority routing Chart, data in Kms 26
  • 28. Figure 11: Existing Priority chart for Jail Rd Control room The Priority Routing involves more parameters than assumed, such as licensing issues and capacity considerations. Jail Road control room consists of 19 LCVs. 13 of which are contracted to Chowdhary transport and 6 through Orient Transport. There exist two Daughter and six Daughter stations under this control room and therefore a well planned and executed priority route results in considerable monetary and energy savings. 27
  • 29. Hazardous Area Classification of a CNG Station 28
  • 30. Hazardous Area Classification of a CNG Station OISD, OIL INDUSTRY SAFETY DIRECTORATE (Government of India, Ministry of Petroleum and Natural Gas) issues a Safety Standard for the operation and distribution of city Gas. A major aspect of understanding Hazardous Areas is to classify them on the basis of the surroundings and the kind of materials present. Such classification can be found in the National Electric Code (NEC), which is a standard for classifying Dangerous locations on operational and breakdown basis. It also includes dangers from all sorts of materials which may be present such as foam, plastics, combustible dust, etc. 29
  • 31. The Cascade cylinder storage area and the compressor area have been classified as Class I - Division I as these handle high pressure Natural Gas (Group I), which is present in the atmosphere at all times of normal functioning and require acute attention in case of a failure or breakdown. The dispensing area has been classified as one which is the most prone to Hazards as vent gas is always present in considerable quantities, under normal functioning. Under an event of mechanical failures in the tubing etc. this area would be highly dangerous as the General Public accesses this area for CNG refilling. The Filtration and Metering skid Area is classified as Class II – Division II –Group E,F,G as combustible dusts of all composition is present in the incoming Natural Gas and proves to be harmful in case of maintenance operations. 30
  • 32. Data for Pressure drop in piping at Suction Buckhardt Compressor date: 25th June2011 Engine gas Flow: 24.8888889 Kg/hr Engine Inlet Suction Flow meter: 670.555556 Kg/hr (ρ) Density at 15.07 bar, 29.07oC: 9.483 (kg/m3) Volumetric flow rate: 70.71133 (m3/hr) (Q) Volumetric flow rate: 0.01964 (m3/s) (D) Diameter of pipe (2”): 0.0508 (m) (v) Velocity: 9.695929 (m/s) (T) First stage Suction temperature: 29.07 oC (µ) Viscosity of gas at 15.07 bar, 29.07oC: 1.182*10-5 (kg/m.sec) (k) Kinematic viscosity of gas: 1.25*10-6 (m2/sec) (Nre) Reynold’s number: 395194.37 Formulae used Volumetric flow rate: (Mass flow rate)/Density Flow (m3/hr)/3600 : Flow(m3/s) Velocity of Flow: Volumetric flow rate/Cross sectional area of Flow (πD2/4) Kinematic Viscosity: Dynamic Viscosity/density Reynolds number: (Diameter*Velocity)/kinematic Viscosity 31
  • 33. 32
  • 34. 33
  • 35. 34
  • 36. Assumptions for Calculations Natural Gas is assumed to be 100% Methane, and properties of Methane at Low pressure and High Pressures assumed to be properties of Natural gas at the given Pressures and Temperatures. Moody diagram for coefficient of friction has been linearly interpolated between known values to obtain an approximate coefficient for a given Reynolds number and roughness factor. Pressure regulation Valves (PRVs) etc. equipment at the metering Skid have been assumed to result in zero pressure loss. 35
  • 37. Figure 12: Moody diagram (Ref: College of Nautical Sciences, Glasgow) 36
  • 38. Comparative Data for Pressure Drop in Tubing Mass Flow rate: 300 Kg/hr Pressure: 250 bar Thermodynamic properties of Gas at 250 bar and 21oC Density (ρ): 192.46225841658 Kg/m3 Viscosity (µ): 2.38456076692404*10-5 N.s/m2 Compressibility (Z): 0.852039803268427 Kinematic Viscosity (ν): 1.23897578*10-7m2/s Volumetric Flow Rate: 1.558747m3/hr Volumetric Flow Rate (Q): 4.32985278*10-4m3/s Tubing data: 3/4" Tubing 1” Tubing 5/4” Tubing Outer Diameter (O.D.) 1.9cm 2.54cm 3.175cm Thickness* (from Table 1) 0.095” 0.12” 0.156” Internal Diameter (D) 0.014174m 0.019304m 0.023825m Roughness (k) (Table 2) 0.00008m 0.00008m 0.00008m Roughness Factor(k/D) 0.00564 0.00414 0.00335 Velocity of Gas (v) 2.74409026 m/s 1.47941028 m/s 0.971219582 m/s Reynold’s Number (Nre) 3.13837927*105 2.30501165*105 1.86761573*105 Coefficient of Friction(λ) 0.032 0.029 0.028 (Fig) Length of Tubing (L) 10 m 10 m 10 m Pressure loss (ΔP) using 16364.1139 Pa 3164.05144 Pa 1067.13748 Pa Formulae Pressure Loss (ΔP) 0.16364.1139 bar 0.0316405144 bar 0.0106713748 bar 37
  • 39. Table for Tubing Data (Parker Hannifin Corp.) Table 2: Maximum Allowable Working Pressure for Tubing *Thickness of tubing required to handle Maximum allowable Working Pressure assumed to be the next higher available value of pressure above 300bar 38
  • 40. Roughness of Materials Aluminium, drawn/pressed New 0.0013 - 0.0015 mm Aluminium, drawn/pressed Used to 0.03 mm Brass, drawn/pressed New 0.0013 - 0.0014 mm Brass, drawn/pressed Used to 0.03 mm Cast iron average city severage 1.2 mm Cast iron Incrusted to 3.0 mm Cast iron new, bituminized 0.10 - 0.13 mm Cast iron new, with skin 0.2 - 0.6 mm Cast iron operating several years, cleaned 1.5 mm Cast iron slightly rusty 1.0 - 1.5 mm Copper, drawn/pressed New 0.0013 - 0.0015 mm Copper, drawn/pressed Used to 0.03 mm Glass, drawn/pressed New 0.0013 - 0.0015 mm Glass, drawn/pressed Used to 0.03 mm Steel after long operation cleaned 0.15 - 0.20 mm Steel homogeneous corrosion pits 0.15 mm Steel intensely incrusted 2.0 - 4.0 mm Steel slightly rusty and incrusted 0.15 - 0.40 mm Steel, longitudinal welded new, bituminized 0.01 - 0.05 mm Steel, longitudinal welded new, galvanized 0.008 mm Steel, longitudinal welded new, rolling skin 0.04 - 0.1 mm Steel, weldless new, comm.size galvanized 0.10 - 0.16 mm Steel, weldless new, neatly galvanized 0.07 - 0.10 mm Steel, weldless new, pickled 0.03 - 0.04 mm Steel, weldless new, rolling skin 0.02 - 0.06 mm Steel, weldless new, unpickled 0.03 - 0.06 mm Table 3 Roughness of Materials 39
  • 41. Grades of Steel Used: The Society of Automotive Engineers (SAE) designates SAE steel grades. These are four digit numbers which represent chemical composition standards for steel specifications. The American Iron and Steel Institute (AISI) originally started a very similar system. Over time they used the same numbers to refer to the same alloy, but the AISI system used a letter prefix to denote the steelmaking process. Carbon and alloy steel Carbon steels and alloy steels are designated by a four digit number, where the first digit indicates the main alloying element(s), the second digit indicates the secondary alloying element(s), and the last two digits indicate the amount of carbon, in hundredths of a percent by weight. For example, a 1060steel is a plain-carbon steel containing 0.60 wt% C. Major classifications of Steel SAE designation Type 1xxx Carbon steels 2xxx Nickel steels 3xxx Nickel-chromium steels 4xxx Molybdenum steels 5xxx Chromium steels 6xxx Chromium-vanadium steels 7xxx Tungsten steels 8xxx Nickel-chromium-vanadium steels 9xxx Silicon-manganese steels SAE designation Type Carbon steels 10xx Plain carbon (Mn 1.00% max) 11xx Resulphurized 12xx Resulphurized and Rephosphorized 15xx Plain carbon (Mn 1.00% to 1.65%) 40
  • 42. Manganese steels 13xx Mn 1.75% Nickel steels 23xx Ni 3.50% 25xx Ni 5.00% Nickel-chromium steels 31xx Ni 1.25%, Cr 0.65% or 0.80% 32xx Ni 1.25%, Cr 1.07% 33xx Ni 3.50%, Cr 1.50% or 1.57% 34xx Ni 3.00%, Cr 0.77% Nickel-chromium-molybdenum steels 43xx Cr 0.50-0.95%, Mo 0.12-0.30% 47xx Ni 1.82%, Cr 0.50-0.80%, Mo 0.25% Ni 1.82%, Cr 0.50%, Mo 0.12% 81xx V 0.03% min 81Bxx Ni 1.05%, Cr 0.45%, Mo 0.20% 86xx Ni 0.30%, Cr 0.40%, Mo 0.12% 87xx Ni 0.30%, Cr 0.45%, Mo 0.12% 88xx Ni 0.55%, Cr 0.50%, Mo 0.20% 93xx Ni 0.55%, Cr 0.50%, Mo 0.25% 94xx Ni 0.55%, Cr 0.50%, Mo 0.35% 97xx Ni 3.25%, Cr 1.20%, Mo 0.12% 98xx Ni 0.45%, Cr 0.40%, Mo 0.12% Nickel Ni 0.55%, Cr 0.20%, Mo 0.20% molybdenum 46xx Ni 1.00%, Cr 0.80%, Mo 0.25% Chromium steels Ni 0.85% or 1.82%, Mo 0.20% or 0.25% 50xx Ni 3.50%, Mo 0.25% 50Bxx Cr 0.27% or 0.40% or 0.50% or 0.65% 51xx Cr 0.50%, C 1.00% min 51xxx Cr 0.28% or 0.50% 51Bxx Cr 0.80%, 0.87%, 0.92%, 1.00%, 1.05% 52xxx Cr 1.02%, C 1.00% min 41
  • 43. Stainless Steel SS316— The second most common grade (after SS304); for food and surgical stainless steel uses; alloy addition of molybdenum prevents specific forms of corrosion. It is also known as marine grade stainless steel due to its increased resistance to chloride corrosion compared to type SS304. SS316 is often used for building nuclear reprocessing plants. SS316L is an extra low carbon grade of SS316, generally used in stainless steel watches and marine applications, as well exclusively in the fabrication of reactor pressure vessels for boiling water reactors, due to its high resistance to corrosion. Also referred to as "A4" in accordance with ISO 3506, SS316Ti includes titanium for heat resistance, therefore it is used in flexible chimney liners. 42
  • 44. An example of how the Cascade System Utilizes a Three Stage Storage Bank to Provide a More Efficient System than the Single Control Volume Storage Supply An article published by RP publishing written by Ralph O. Dowling of C.P. Industries is summarized in this section to better describe the cascade system. The cascade system as mentioned earlier is a more efficient system than the single control volume storage supply. A brief description of how the cascade operates will be described in the following paragraphs. An understanding of the effects of compression on natural gas is the first step in understanding the cascade system. 43
  • 45. Table 4: Pressure - scm Natural Gas filled per Unit Volume Table 3 illustrates how Natural Gas is affected when compressed into the same volume as occupied by 1m 3 of water. It gives the amount of natural Gas in standard cubic metres(scm) that would occupy 1m3 Volume at a given pressure. 44
  • 46. Storage System for Fast Fill: CASCADE A cascade system is comprised of three banks (low, medium, high), which are high pressure storage vessels. The whole cascade system holds about 891.96 scm of Natural Gas at 250bar. These are deployed in two different configurations: 40 cylinder of 75 Ltr capacity and 50 cylinders of 60 Ltr capacity. Considering 40 X 75 liter configuration, each of the vessels has a water volume of 0.075 m3, which would be 3 m3 total water volume. Banking cascade storage vessels have a design pressure of 275 bar and a storage pressure of 250 bar. At 250 bar each storage vessel will contain 22.299 scm of natural gas (0.075 m3* 297.32 scm / m3 water = 22.299 scm) at 210C. From Table3, at 250 bar, the volume of Natural Gas is 297.32 scm / m3 water. The Total Natural Gas contained in the system if all three stages are at 250 bar and 21oC would be 891.96 scm (22.299 * 40). The following assumptions have been made for the cascade sequence explanation: Manual cascade system 1. Temperature remains constant 2. Each vehicle cylinder has a water volume of 65liters (0.065 m3) 3. The vehicle cylinder will contain 16.40 scm of natural gas at a pressure of 200bar 4. Each vehicle cylinder(s) is initially empty 5. No replenishment of the cascade bank during the refueling cycle The liquid volume (empty) of the vehicle cylinders can be calculated by dividing the specified capacity at 200bar (16.40 scm) by the amount of gas in scm (from Table 3) contained in 1m3 liquid volume at 200bar. So the total water volume of the vehicle cylinder would be 16.40 scm / (252.33 scm / m3) = 0.065 m3 45
  • 47. Cascade as a Single Control Volume The Cascade is first taken to be a single control Volume of 40 cylinders of 75 liter Water Capacity each. Total Capacity is 3000 (75*40) Water Liters at 250 bar. The Available quantity of Natural Gas to be dispensed at 200 bar would be the difference of scm of Natural gas held in the Cascade at 250 bar and at 200 bar from Table3. Amount of Natural Gas per m3 water at 250 bar: 297.32 scm Amount of Natural Gas per m3 water at 200 bar: 252.33 scm Water Capacity of cascade: 3m3 Available Qty of Natural Gas to dispense: (297.32-252.33)*3 = 134.97 scm Number of Vehicle cylinders filled: (134.97/16.40) = 8.229 Therefore approximately Eight (8) vehicle cylinders can be completely filled at 200 bar from a 3000 water liter cascade at 250 bar without the compressor having to recharge the cascade. 46
  • 48. Cascade as a Banking System The Cascade is now divided into separate Banks (Low-med-High) based on the priority with which they fill the vehicle cylinder. The Ideal configuration is 50% of all cylinders be deployed for Low Bank, 30% Medium bank, 20% High Bank Out of 40 cylinders in the Cascade Low bank cylinders: 25 Medium bank cylinders: 10 High Bank cylinders: 5 Now, assume that the First NGV is ready to be serviced. The first vehicle can be completely filled from the low storage bank without having to switch to the next storage bank. The low bank contains 557.475 (=22.299*25) scm of natural gas at 250 bar, after the first vehicle is serviced, the low bank will contain 541.075 scm (557.475 – 16.40) of natural gas at (541.075/1.875) = 288.573 scm / m3 From Table 3 interpolate 288.573 scm / m3 to find the pressure in low storage bank after the first NGV has been filled (239.57 bar). The Second vehicle is now ready for service. The next vehicle can also be filled to the 200 bar level from the low bank. The medium bank will not have to be used yet. The second vehicle will be filled from the low bank until the pressure in the low bank and the NGV pressures equalize. The same mathematical process for the first NGV example must be done for the second. 524.675 scm (541.075 -16.40) of Natural gas remains in Low Bank at (524.675/1.875) 279.82 scm / m3. From Table3 interpolate 279.82 scm / m3 to find the pressure in the low storage bank (229.24 bar). 47
  • 49. After the Third vehicle is serviced, 508.275 scm (524.675-16.40) of Natural Gas remains in Low Bank at (508.275/1.875) 271.08 scm / m3, which corresponds to (218.90 bar) pressure. After the Fourth vehicle is serviced, 491.875 scm (508.275-16.40) of Natural Gas remains in Low Bank at (491.875/1.875) 262.33 scm / m3, which corresponds to (210.28 bar) pressure. After the Fifth vehicle is serviced,475.475 scm (491.875-16.40) of Natural Gas remains in Low Bank at (475.475/1.875) 253.58 scm / m3, which corresponds to (201.67 bar) pressure. The Sixth vehicle cannot be filled to the 200 bar level from the low bank. The medium bank will now have to be used to top off the vehicle. The sixth vehicle will initially be filled from the low bank until the pressure in the low bank and the NGV pressures equalize. For that, we find the equalization pressure of the Low Bank with the NGV cylinder, which is the pressure corresponding to (Available quantity of gas) / (Volume of Low Bank + Volume of NGV cylinder) = 475.475 / (1.875+0.065) scm gas/m3 = 245.09 scm gas/m3, which from Table3 corresponds to 193.05 bar pressure. Since the low storage bank and the NGV are equalized, the NGV cylinder(s) now contain a pressure of 193.05 bar (< 200 bar), the NGV must be topped off by the medium storage bank to achieve the desired 200 bar fill level. The low bank now contains 459.543 scm (245.09 scm/m3 * 1.875m3) of natural gas. The vehicle now contains 15.93 scm of natural gas (0.065m3 * 245.09 scm / m3) The medium storage bank must provide 0.47 scm (16.40 scm – 15.93 scm) of natural gas to top off NGV number 6. The Medium Bank contains 222.99 scm (22.299*10) of Natural Gas. The same mathematical process as before must be compiled to determine the remaining pressure. 48
  • 50. (222.99-0.47) / 0.75 m3 = 296.693 scm / m3 Using Table3, interpolate 296.693 scm / m3 to determine the total pressure remaining in the Medium storage Bank (248.21 bar). This method of calculating total volume and total pressure remaining can be applied to fill process from a cascade system for Sixteen (16) NGVs. The first Sixteen vehicles can be filled from the Low and Medium storage banks only with the Low storing bank containing (326.85 scm at 136.16 bar) and the Medium storage bank containing (191.150 scm at 201.67 bar) after the Sixteenth NGV has been filled. NGV number 17 will have to be filled from the low, medium, and high storage banks. The Seventeenth vehicle will first equalize pressure with Low storage bank (132.71 bar) 326.85 scm / (1.875 + 0.065) m3 = 168.479 scm / m3 Through interpolation using Table3 the equalization pressure would be 132.71 bar. After an initial fill from the Low storage bank, 10.95 scm of natural gas would be contained in the NGV cylinder (0.065 m3 * 168.479 scm / m3). NGV number 17 will now equalize pressure with the Medium storage bank (196.50 bar). With 191.150 scm remaining in the Medium storage bank, the pressure in the Medium storage bank and the NGV cylinder will equalize pressures. (191.50 + 10.95) scm / (0.75 + 0.065) m3 = 247.97 scm / m3 Through interpolation using Table3 the equalization pressure would be 196.50 bar. After the Low and Medium storage banks have gone through the equalization process, the High storage bank must be utilized to top off the vehicle. NGV number 17 now contains 16.11 scm (0.065 m3 * 247.97 scm / m3) of natural gas. With the NGV containing 16.11 scm of natural gas, 0.29 scm (16.40 scm – 16.11 scm) must be added to achieve the full fill level for NGV number 17. The high bank has a capacity of 111.495 scm (22.299*5) of Natural Gas. The remaining natural gas in the high bank would be 111.205 scm (111.495 scm – 0.29 scm) at a pressure of 248.21 bar. 111.205 scm / 0.375 m3 = 296.54 scm / m3 49
  • 51. Through interpolation, using Table3, the pressure remaining in the third storage bank would be 248.21 bar. If this process is continued, 25 NGVs can be filled before this cascade system will need to be recharged by the compressor. If a single control volume storage system were used instead of cascading, only 8 vehicles could be recharged before the system would have to be replenished by the compressor. The Following Table compares the efficiencies of the two systems. Number of Natual gas Natural gas Efficiency of vehicles capacity of capacity (scm) of system = (# of that can be each NGV system when vehicles * NG System fueled (scm) fully capacity of each by the particular charged NGV) / NG system capacity of the system Cascade 25 16.40 891.96 45.96% Single Control 8 16.40 891.96 14.71% Volume 50
  • 52. Suggestions for better safety and services 1. PNG a. It is suggested to have Fuming Strips (perforated strips with smelling agent) of mercaptin (Ethyl or methyl) to be supplied annually along with the Gas consumption bill along with an instruction sheet which asks the consumer to make each family member sniff the Strip and have an idea about the smell which indicates them the presence of any form of leakage in the supply system or flow meter. This would enable the consumer to be able to detect / prevent a major Hazard. 2. CNG a. I have strongly felt the need for the existence of regular Awareness Camps at filling stations where consumers get to witness the immediate remedial steps needed to be taken in case of an emergency within the car. i. There should be Fuming Strips which replicate the smell of gas leakage at the concentration at which it exists in the car. ii. The camp should display protocols to be followed step by step in case of an emergency’ depicting various complications which may arise and ways to counteract them. iii. The camp also shows the dangerously high pressures that exist in various tubings within the car and how lethal such high pressures can be. Citing common examples of the muzzle pressure inside an AK47 making the audience experience a gauge pressure of 1bar on their hands and explaining how dangerous a 200bar pressure stream can be. Consumers also need to be repeatedly told about common characteristic properties of the Natural Gas. b. Every filling attendant must be given the authority to issue non-compliance papers to CNG vehicles. Where any vehicle found to have dangerous / worn out nozzle receivers(female) would be advised to get it changed within a stipulated time period (suggested:1 Month). Failing which, CNG 51
  • 53. will not be dispensed to the vehicle. This is in direct accordance towards the safety of the filling attendants as dangerous recoils and snake sliding in the hose occurs due to ineffective contact between the O-rings and the female nozzle walls. The current inspection of cylinders at 5 years and tubing at 1 year does not take into consideration normal daily wear and faults which need immediate attention. The attendants have been entrusted with such responsibilities as they witness hands-on the exact state and seriousness of the issue. 3. CNG Filling Stations a. UTILISING VENT GAS i. Vent gas which is released into the atmosphere in order to break the gas flow path in the dispenser nozzle so that it can be disconnected from the vehicle should be utilized. A few suggested uses of the gases (need of further experimentation required): 1. Producing electricity (the gas at approx 200bar can be effectively used to produce energy by expansion over a turbine and later combusted to produce a considerable amount of energy to power the Flood lights on a filling station. 2. The gas can be collected over an overhead container where all the dispensers release their vent gas and this gas can be later combusted to produce energy to power the infrastructure around a CNG Filling station. 3. Implementation of SCADA, in order to effectively monitor various units under a control room at once and result in swift delivery of services and prompt servicing. 4. Quick licensing of compressor packages in order to result in less effective kilometer usage on transport of LCV’s and ease in meeting rising gas demands. (eg: licensing of compressor package at Dwarka sec-20 filling station would result in a net saving of 10 Km per LCV filling trip) 52
  • 54. References D. Rood, ”A practical guide to care, maintenance and troubleshooting of capillary Gas Chromatographic systems“, 2nd edition, Hüthig Verlag, Heidelberg, 1995 Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003). Materials and Processes in manufacturing (9th edition.). Wiley. Jeffus, Larry F. (2002). Welding: Principles and Applications. Cengage Learning. Dowling, Ralph O., .Cascade Basics, RP Publishing, 1993. Moran, Michael J., Shapiro, Howard N., .Fundamentals of Engineering Thermodynamics., John Wiley and Sons Inc., New York, pp. 488-449, 1999. Tubing manual and selection Guide, Product Catalogue: Parker Hannifinn Corporation, 2007 Ronald A. Hites Mass Spectrometry Gas Chromatography National electric code (NEC), National Fire protection Association (NFPA), Batterymarch Park, Quincy, MA 53