Introduction
The High-flow LNG Refueling Pump Skid is a pre-assembled pumping system designed to transfer liquefied natural gas from storage tanks to refueling dispensers or mobile fueling systems.
Product Specification
|
Item |
Specification |
|
Rated flow capacity |
Up to 300 L/min (79 GPM) |
|
Operating pressure |
Up to 1.6 MPa |
|
Truck fueling time |
< 5 minutes per vehicle |
|
NPSHr |
< 0.2 m (submerged pump) |
|
Pump type |
Submerged cryogenic pump |
|
VFD speed range |
1,500 – 3,600 RPM |
|
Control method |
Real-time pressure feedback control |
|
Cooldown time |
~12 minutes from ambient |
|
BOG control |
Reduced boil-off during startup |
|
Operating temperature range |
-40°C to +55°C |
Product Configuration
|
Item |
Specification |
|
PLC platforms |
Allen-Bradley CompactLogix / Siemens S7-1500 |
|
HMI size |
12-inch explosion-proof touchscreen |
|
HMI data display |
RPM, suction/discharge pressure, vacuum levels |
|
Communication protocols |
Modbus TCP/IP, Profinet, EtherNet/IP |
|
Remote diagnostics |
Cloud-based VPN telemetry |
|
Automated sequences |
Cooldown / leak check / fueling / venting / standby |
|
UPS backup |
Up to 45 minutes |
Applications
Drop-in footprint designed for direct replacement at retail fuel stations and private fleet depots without site re-engineering.
Dual horizontal or vertical LNG storage tank flanged connections with dedicated liquid and vapor return tie-ins to match existing facility layouts.
Dual-hose configuration supporting two Class 8 trucks fueling concurrently while maintaining a stable flow rate above 120 L/min per hose.
Optional C5-M anti-corrosion coatings and IP66 stainless steel electrical enclosures to eliminate yearly re-coating maintenance in high-salinity environments.
OEM/ODM Engineering & Customization
Layout Modifications
Structural footprint and piping alterations completed within 10 business days to fit restricted site geometry or existing concrete containment dikes.
AVL Component Integration
Custom procurement options to match your corporate Approved Vendor List (AVL) for all cryogenic valves, transmitters, and flowmeters.
Open Control Systems
Unencrypted PLC source code provided upon delivery for independent field integration with existing site DCS or SCADA networks.
1-Unit MOQ for Pilot Sites
Custom structural, mechanical, or piping modifications available starting from 1 single unit to support infrastructure field trials.
Manufacturing Capabilities
Scalable Output: 15,000 m² dedicated assembly facility delivering a proven manufacturing capacity of 25 completed LNG skids per quarter.
100% Cryogenic Loop Testing: Pre-shipment Factory Acceptance Testing (FAT) executed with liquid nitrogen (LN2, -196°C) to verify mechanical seal integrity and VFD performance curves.
Certified Welding & Assembly: Structural and pressure welding executed by technicians certified to AWS D1.1 and EN ISO 9606-1; valve packing handled in Class 10,000 cleanrooms.
Complete MDR Delivery: Every shipset includes a comprehensive Manufacturing Data Report (MDR) containing FAT records, P&ID redlines, loop checks, and NDT reports.
Lifecycle & Maintenance Support
Submerged pump bearing configurations operate for 10,000 hours before requiring scheduled inspection or maintenance downtime.
Open access corridors within the structural frame allow one technician to replace valves and transmitters without dismantling main piping loops.
Preventative maintenance kits stocked in regional hubs for 48-hour dispatch; Mean Time to Repair critical instrumentation is under 90 minutes via modular pull-out brackets.
Comprehensive 2-year warranty covering all structural, mechanical, and factory-assembled piping under continuous field operations.
Compliance Verification
Third-Party Certification: Documented TÜV / S&P / DNV Type Approval and ≥72-hour continuous liquid nitrogen (LN2) cryogenic performance validation log.
Global Track Record: Verified field operations across North America, Europe, and Southeast Asia, with each single refueling station exceeding 8,000 hours of cumulative grid operation.
Explosion-Proof & Regulatory Compliance: Certified under ATEX Zone 2 and IECEx standards, with technical alignment to European LNG station regulations EN 14678-1 and EN 14678-2.
Maintenance & Lifecycle OPEX: Verified system MTBF of 9,000 to 12,000 hours, dynamic sealing service life over 4,000 operating hours, and an annual wear-parts replacement rate under 5% for a predictable 10-year cost structure.
Audited Quality Management: Facilities operate under ISO 9001:2015, ISO 14001, and ISO 45001 certifications, open to annual third-party compliance audits.
FAQ
Q: What is the typical commissioning time for the LNG pump skid after delivery?
A: The skid can be installed and fully commissioned within 5–7 days when the foundation and LNG supply lines are ready. This includes piping connection, nitrogen purge, and a full cryogenic validation test.
Q: How many real LNG stations is this system currently operating in?
A: The system has been deployed in over 60 operational LNG refueling sites across Southeast Asia, Europe, and North America. Average continuous runtime per site exceeds 8,000 operating hours.
Q: What is the verified maintenance cost over a 10-year lifecycle?
A: The total maintenance cost is typically 12–18% lower than conventional cryogenic pump systems due to the submerged pump design and modular replacement structure. A major overhaul is usually required only after 8–10 years of operation.
Q: What certifications can be independently verified?
A: The system is certified under DNV type approval, TÜV cryogenic safety validation, and IECEx Zone 2 compliance. Full certificates are available for third-party verification upon request.
Q: How stable is the flow performance during continuous truck fueling?
A: During dual-hose operation, each line maintains a stable flow of 120–160 L/min without pressure drop fluctuation greater than ±3%. This stability is maintained even during back-to-back truck fueling cycles.
Q: What is the expected service life of the submerged cryogenic pump?
A: The pump is designed for a service life of approximately 9,000–12,000 operating hours before major inspection. Seal components typically require replacement every 4,000–5,000 hours depending on usage intensity.
Q: How does this system compare with conventional above-ground LNG pump systems?
A: Compared to traditional systems, this skid reduces startup cooldown time by about 35% and improves energy efficiency by approximately 10–15%. It also significantly reduces vapor loss during transfer operations.
Q: What safety mechanisms are included in emergency conditions?
A: In case of abnormal pressure or leakage detection, the system initiates automatic shutdown within 2–3 seconds. It also activates controlled venting and isolates liquid lines to prevent cascade failure.
Q: Can the system integrate with existing station SCADA systems?
A: Yes, it supports full integration with SCADA platforms via Modbus TCP/IP, Profinet, and EtherNet/IP protocols. Open control architecture allows direct mapping to existing control logic.
Q: What is the typical return on investment period for operators?
A: Based on average station throughput, ROI is typically achieved within 2.5 to 4 years due to reduced downtime, lower energy consumption, and faster truck turnaround time.
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