CNG fueling stations ten to fifteen years old are approaching their service midlife.

InsightFuel has a station repair and upgrade practice that quickly and cost-effectively brings old stations into compliance with new code and current best practices.

A graph of CNG stations by build year.

A graph of CNG stations by build year.

Older stations frequently have an “improvised look” as installers routed electrical and gas lines by hand when encountering obstacles like caissons. We work with the station owner to identify areas where repairs and upgrades are needed.  We go through a process leading to the creation of a Standard Work document.  With everyone on the same page, we can generate an accurate estimate for repairs and begin prefabricating materials in our shop in order to minimize disruption and time on site.

Station Repair Standard Work Example

An example of our Standard Work. This enables us to ensure everyone is on the same page.

Expansion Loops

It is natural for tubing to expand and contract with changes in temperature, causing them to flex and bow. We can replace these bowed sections with prefabricated expansion loops, which allows the tubing to expand and contract without causing structural or cosmetic damage.

flexed pressured supply line

Pressured supply lines expand and contract with temperature changes.

The expansion loop extends the service life of the supply lines

The expansion loop extends the service life of the supply lines by preventing bowing.

Electrical and gas lines were routed by hand around obstacles like caissons.

Electrical and gas lines were routed by hand around obstacles like caissons.

Expansion loops can replace the routing to be safer as well as more aesthetically pleasing.

Expansion loops can be used to replace the routing to be safer as well as more aesthetically pleasing.

Repairs

Over time, station materials begin to show their age.  Usually the weather damage is only cosmetic, but sometimes it’s also functional, posing a safety hazard. Our technicians are able to repair or replace these structural items as well.

Rusted Pipe Support

This pipe support has rusted due to being exposed to the elements over time.

Repaired Pipe Support

Repaired pipe support.

Service Line Upgrades

Older stations were designed to use the materials available when they were built.  Today stations are built with larger diameter lines giving better gas flow to fueling points.

Older stations frequently used ½” tubing to carry all of the volume from the compressor(s) to the fueling points.  These small diameter runs needlessly restrict flow.  Furthermore, many lines were pulled through the same PVC chase.   Placing multiple tubing runs in a single chase is not recommended any longer, but was frequently done in the past.  Tubes can rub against one another as the gas flow is started and stopped during fuel dispensing. Repeated rubbing can lead to failure of the tubing.

Most stations can be retrofitted with larger diameter tubing and prefabricated sweeps to improve flow.   We install each tube in a separate chase.

The frequently used 1/2

The frequently used 1/2″ tubing needlessly restricts flow from the compressors to the fueling points.

Over time, tubes rub together

Tubes rub together which can lead to failure, over time.

Here we are pulling larger 3/4

Here we are pulling larger 3/4″ tubing through existing MDPE.

Flexible HDPE chase

Flexible HDPE chase.