Gas filling station

LPG enters the base in two ways: either through a pipeline from an oil refinery, or by rail in tank cars (in this case, they are emptied on a special drain rack). Then it goes to storage in the GNS tank farm. Empty cylinders are delivered to the filling point (workshop). Depending on the performance of this section, it is possible to use various means of mechanization of the unloading process manually, or using various types of conveyors (disk, chain, roller sliding, overhead, etc.). In addition, recently they have become widespread, especially in developed countries, where there is a strong tendency to switch from expensive manual labor to the use of industrial robots, pallet unloading systems . Pallet plants are available in different versions: from systems with manual (for gas filling stations of small capacity) or semi-automatic control to fully automatic. One of the consequences of the introduction of the pallet system is the division of transport into “external”, delivering cylinders from consumers to the STS, and “internal”, moving pallets with cylinders inside the STS. At the same time, drivers from “external” vehicles do not enter the internal territory.

Since the cylinders do not manually lift, this system minimizes the number of work-related injuries. Also, during transportation in pallets, the cylinders are protected from possible mechanical deformations, which helps to preserve the geometric shape and color. The equipment of a point (or workshop) for filling cylinders directly depends on the required interchangeable capacity of one or another standard size. Accordingly, they can be equipped with both compact filling systems and roundabout installations of high productivity. In general, there are many technological solutions for organizing the process of refueling gas cylinders.

A linear filling system using manual or semi-automatic filling stations is designed for a throughput of 50-250 cylinders per hour. Conveyor belt using refueling carousels. Such systems are suitable for refueling any type of cylinder and can be built on the basis of both chain and roller conveyors.

To account for the released gas, the principle of weighing or the principle of mass flow can be used. From 1 to 8 refueling machines can be put in one refueling line, when designing linear systems, you can take into account and plan the future increase in productivity in the layout solution.

Rotary filling systems with a capacity of up to 1800 cylinders per hour are semi-automatic or fully automatic, depending on the type of valve used. The level of automation can be changed according to needs.

From 8 to 42 refueling units can be located on the carousel platform in accordance with the required capacity. All equipment within the danger zone: chain conveyor, entry and exit points, fueling carousels and fueling devices, control scales, sorting conveyor, leak detector; The data and power interface is manufactured in explosion-proof version. Equipment in a non-hazardous area is limited to a computer with a modem and printer and can be placed in any convenient place outside the danger zone.

The basis of all the above systems is a refueling machine designed for safe and efficient filling of all types of cylinders (of various diameters, heights, both with valves type KB-2 and valves type VB-2). To control the flow of the product, the principle of weighing (electronic balance) or the principle of mass flow can be applied. When weighing, it is necessary to have empty cylinder data to determine the exact dose of LPG filling in accordance with the norm established by the regulation.

Control weighing systems are also available with manual, semi-automatic or fully automatic control. The following system designs are possible:

• on line in a chain conveyor with a lifting table for stationary control weighing or with a dynamic table for continuous control weighing;
• on line in a chain conveyor for fully automatic control weighing with automatic

the transfer of tare from the central coding station (if available on the STS);

• on line in a chain conveyor for semi-automatic control weighing with manual coding

tare weights;

• on line in a chain conveyor for semi-automatic control weighing with packaging reconciliation, which

carried out by the operator;

• stationary control scales for installation on the floor.

The auxiliary equipment used to fill the cylinders includes various devices, both involved directly in the filling process, and in the process of preparing for it. These devices include:

• machines for checking the orientation of the valve to perform an auxiliary function in conjunction with manual or automatic filling of cylinders with valves of the VB-2 type ;
• machines for opening and closing cylinders with valves of the VB-2 type to replace manual labor, automation and acceleration of the production process;
• drain systems used to drain condensate and empty the cylinders before repairing them, as well as to drain overfilled cylinders;
• apparatus for replenishing / draining surpluses ", designed to adjust the weight of the product in a filled cylinder and to bring the weight of LPG to normal in incorrectly filled cylinders;

• electronic and manual gas leak detectors for detecting leaks of the vapor phase of LPG from under the valve of the cylinder, as well as on the valve seat, in manual or fully automatic mode, as well as bathtubs for monitoring leaks ;
• valve replacement machines used in the repair of cylinders;
• cylinder purge systems used for quick and safe displacement of atmospheric air by the vapor phase of LPG;
• equipment for internal cleaning and inspection of LPG cylinders , necessary during the re-examination of cylinders;
• equipment for checking cylinders with pressure with a maximum capacity of up to 450 cylinders per hour and test pressure up to 4.5 MPa;
• washing systems for cleaning cylinders of all types of dirt and lubricants;
• machines for straightening the surfaces of handles and base rings of cylinders
• equipment for surface treatment of cylinders , which includes various mechanisms and devices for cleaning and painting;
• machines for preparing decommissioned cylinders for disposal , bringing decommissioned cylinders into a condition unsuitable for further unauthorized use;
• equipment for marking cylinders ;
• shrink cap systems
• data management systems designed to collect, process and transmit data from operating refueling and other technological devices

• The installation of the VB-2 valve on steel welded cylinders for LPG with a pressure of 1.6 MPa is regulated by GOST 21804-94 and GOST15860-84.

• Industrial gas equipment : Handbook, 6th ed., Revised. and add. / ed. E. A. Karyakina - Saratov: Gazovik, 2013 .-- P.1121 ISBN 978-5-9758-1209-4
• Equipment for liquefied petroleum gases : Handbook, 1st ed. / Under. ed. E. A. Karyakina - Saratov: gas industry worker, 2015 .-- P.521 ISBN 978-5-9758-1552-1
• Karyakin E.A. Equipment for gas filling stations // Gas of Russia. 2015. No. 1. P.68