LPG Station & LPG Filling Plant
The LPG STATION is developed to achieve maximum satisfaction for the consumer and profitability for the investor; and meet public safety regulations of the authorities.
Our concept of “Micro-filling plant” called “LPG STATION” consist of scaled-down professional installation that provides services at a level of safety that equals the traditional filling plant.
On request, we can supply the different components of our standard LPG STATION separately. However, this might create some adaptation difficulties since our LPG STATION was designed as a complete integrated unit. We can also provide some variations to the standard unit such as larger tank capacity.
The LPG Station concept
• To provide a professional, flexible, efficient and reliable unit with proven specialized equipment requiring minimal maintenance.
• To provide a “complete” unit (preassembled) that will be installed very rapidly at minimal costs
• To provide a unit with minimal constraints while meeting International regulations
• To provide a unit that can be operated with minimal staff and lowest operating cost
• Customer convenience and safety. With the LPG STATION concept, the Customer retains own cylinder, which will always be tested for leaks before refill.
Safety, Controllability, efficiency & Investment
• The capacity of the installation has been selected to ensure safety according to International and local regulations.
• Controllability of the equipment means that the scale, working with the computer checks and controls the cylinders and regulates/records the filling process.
• Safety controls. The systems detect it if the cylinder is not empty. This is an important to prevent overfilling. The systems also detect cylinder leakage. These safety measures prevent explosion at the filling point or in the kitchen at home.
• Accountability controls. Different cylinder types and weight will be pre-programmed. Filling can only take place if the cylinder is put on the scale. The system signals the START-STOP of the filling so that volume is accurate. Number of cylinders filled cannot be reset or manipulated. The cabin housing the filling installation is equipped with security locks.
• We have taken great care in the design of its LPG STATION to incorporate reliable and reputable specific LPG equipment and devices to enable a tight operational control.
• With LPG STATIONS gas is available at shorter distance from consumers. The LPG STATION acts as a filling plant and a retail point, which simplifies distribution logistics and minimises costs.
• Compared to traditional filling plants, less equipment, land, operating staff and other running costs are very much less, which means less capital investment.
• The LPG Station requires minimal maintenance and not prone to mishandling by the operator.
• Reduces investment on cylinders. With traditional cylinder filling plants and distribution networks, for each cylinder, at least, one of same capacity, serving as reserve. Basically, you have one cylinder at the filling plant/retail point, one in transit and/or one in the kitchen at customer’s home. With LPG STATION, extra cylinders are not needed. Hence the investment in cylinders can be reduced by half.
• Cylinders exchanges/handling are also minimized meaning longer cylinders’ life-span. During back and forth transportation between the filling plant, the retail points and the Customer’s premises, cylinders or their valves are often damaged. Condition of cylinders also deteriorate when stored on the open subject to sun, rain, sand etc. With LPG Stations, these poor conditions/factors are prevented. Cylinders maintain good condition much longer.
• Our LPG STATIONS can also be sited in villages/rural areas.
• The LPG Stations have been designed with the same (or better) technical standards as the traditional Filling Plants. The pump and the scale of the have the same filling.
• LPG STATIONS enables VERY SUBSTANTIAL FINANCIAL SAVINGS.
LPG STATION GENERAL DESCRIPTION
In the design and construction of our LPG STATION, the quality of equipment and workmanship, reliability, safety and affordability have been taken into consideration. Our goal is to offer the best possible “value for money”.
Our LPG STATION consist of 3 main unit: - cylinder filling cabinet, bulk LPG tank and pumping unit.
Cylinder filling cabinet
• A metallic filling cabinet with frame and panels made of aluminium to resist corrosion without any specific anti-corrosion treatment. It can be installed on an open uncovered space.
• For stability, the cabinet must be secured on the ground.
• Each reinforced side door is equipped with a small storage box for the storage of cylinder caps and seals. Part of the front door opens upward providing additional head-space and shelter against rain and sun to the Operator.
• One powder emergency fire extinguisher is provided.
• The cabinet houses the full ATEX (anti-explosion) general electrical control box with all control buttons including the display in percentage of the magnetic gauge of the tank, emergency push button etc.
• The cabinet is equipped either with 1 or 2 electronic cylinder filling scales for filling any size of cylinders from 2.5 to 50 kg that only require electricity. The filling capacity for each scale is approximately 75 seconds for a 12.5kg cylinder. Depending on the experience of the Operator, the filling capacity could exceed 500 cylinders per day with 2 scales. This is more than the quantity average of filling plant in Nigeria.
• Each scale is equipped with a main tray for all type of cylinder and a folding tray for the filling of small cylinders.
• Each scale is equipped with filling hose that can be terminated with different heads in case multiple valves are in use locally.
• The powerful electronic equipment of the scale performs several other functions including preventing under/over filling of the cylinder, registering all the quantities (gas volume and number of cylinders).
• Each cabinet is equipped with a manual valve leak detector, ATEX lighting, powder extinguisher.
• After working hours, the cabinet can be closed and securely locked to prevent intrusion.
Bulk LPG tank
• Fixed LPG bulk tanks, new, EC standards; either above ground or below ground tank.
• Tank capacity: - 11000 litres (approximately 5 tons), 16000 litres (approximately 7.5 tons) or 21000 litres (approximately 10 tons).
• All tanks are supplied with standard equipment (safety valves, magnetic gauge etc.) Furthermore, for safety the tanks are equipped with solenoid valves that automatically stop the filling at maximum level to prevent dangerous over-filling and stop the running of the pump at low level to prevent damages to the pump if running without liquid.
• A percentage of liquid level as measured by the tank is also reported on the electrical control box visible to the Operator. This enables a close monitoring of the situation and the management of the bulk LPG resupply and tank filling operation.
• Advantages of below ground tanks over above ground tanks include land space recovery and reduces safety distances. Under most countries regulations, under-ground tanks are considered safer.
• As an alternative to using fixed above or below ground tanks, it is possible for the cylinder filling cabinet to be supplied with LPG from a mobile tank such as LPG truck (Bob-tail), semi‑trailer or an ISO-container. In such case we propose the pumping unit to be attached and connected at the back of the filling cabinet that will be connected by pipes to the mobile tanks.
Pumping unit
• The “standard” LPG STATION is equipped with a Pumping unit made up with a three phase 4.5kW, 380-volt WEG electric motor coupled to a 4.0 m3/hr LPG pump. Alternatively, we can supply a pumping unit of lower capacity with a two phase 220-volt 50Hz WEG 1.5kW electrical motor coupled with a 1.5 m3/hr pump. All pumping units are equipped with a bypass for the return of the excess liquid to the tank. The Pumping skid is equipped with all necessary accessories to ensure a smooth operation, filter, pressure gauges, valves etc.
• Pumping unit serve two-ways; for discharging from the trailer-tanker to the bulk tank and for pumping from the bulk tank to the filling unit/cylinders.
• As standard with above ground tanks the pumping skid is installed on the skid itself, under the tank and connected to the LPG bulk tank. For under-ground tanks, the pumping skid is located inside a casing on top of the tank.
• In both cases, the pumping units are connected to the cylinder filling cabinet by LPG pipes provided and ready to be connected.
• Rigid steel pipes and flexible steel mesh pipes.
• In case mobile tanks are used, the pumping unit is attached to the back of the cabinet and connected to the mobile tank flexible hoses.
Others
• Each standard LPG STATION is supplied on Ex-Works, C&F or EPC/turnkey basis. It is “complete” including all electrical cables and connecting LPG piping.
• The assembly on site can be performed in by a non-professional following the provided detailed instructions.
• Under EPC/turnkey projects, the buyer is fully responsible for all local civil engineering, structural and electrical works. Buyer is also responsible and shall provide any material, manpower and labourers that may be required by the seller.
GENERAL INFORMATIONS & COMMENTS
• All equipment are new, meeting EC Standards, specific for the handling of LPG (butane, butane/propane mix or propane).
• The LPG Stations design follows International standards in terms of safety and accuracy that are usually required in traditional large LPG cylinder filling plants.
• We have selected components that have been specifically designed for LPG and have proved their robustness and efficiency.
• Devices that will minimize occasional damages and extend the lifespan of the components are installed.
• We have designed a simple but efficient and reliable leak detection device to ensure the cylinder leaving the station is safe.
• We have made the scale skid enclosable and lockable in a cabinet that can be installed in an open site and can be secured and safe when not in use.
• For safety, we recommend the tank to be enclosed in a wire fence.
• This LPG station only requires a basic and simple training of the Operators. Only 1 or 2 operators are required to operate the LPG station.
• Each LPG Station is pre-assembled and delivered in standard container. It only requires few days for connecting the main elements according to the provided comprehensive assembly and operating manual.
• Connections to a 220 Volts single phase or 380 tetras polar 50hz electrical supply and earthlings and limited civil work.
• Prior to install and operate any LPG installation, it is the responsibility of the Owner to obtain all the necessary agreements and approvals by the concerned Administration and entities.
• The best location to install LPG stations appears to be petrol stations that generally have large space and facility, where to install them safely. Furthermore, in most cases the staff required for a petrol station will be sufficient to also fill cylinders which represent a saving in operating costs. Alternatively, LPG stations can be installed in small industrial sites.
• Additional technical information is available upon request. We will provide any requested technical details necessary authorization/approval certificates.
One important objective has been to provide a reliable installation that will operate with a maximum safety for the people and the equipment and provide the commercial services expected by professionals.