CNG Substation Integrated Compressor

Qingdao Lenado Intelligent Equipment Co., Ltd. is one of the most reliable manufacturers and suppliers of cng substation integrated compressor in China. With a professional production team, we are able to meet the needs of the majority of our customers. Welcome to wholesale bulk customized cng substation integrated compressor from our factory.

CNG Substation Integrated Compressor – All-in-One Skid-Mounted CNG Refueling Equipment
As a leading manufacturer of hydraulic-driven piston pressurization technology for high-pressure fluid applications, Qingdao Lenado Intelligent Equipment Co., Ltd delivers a fully integrated CNG substation compressor that revolutionizes traditional separate CNG substation layouts. This all-in-one skid-mounted unit integrates all core functional modules inside a weatherproof, sound-insulated cabinet, realizing complete unmanned automatic operation for commercial CNG filling stations, small vehicle refueling points and mobile CNG supply stations.
The entire machine assembles critical components including CNG unloading system, gas filter, hydraulic reciprocating compressor, oil & gas circulation cooling system, medium/high pressure gas storage cylinder group, explosion-proof CNG dispenser, PLC intelligent control cabinet and full safety protection system via standardized valve pipelines. Different from split-type CNG substation equipment that requires on-site assembly of scattered parts, our integrated compressor finishes all pipeline layout, wiring and debugging in factory, drastically cutting on-site installation cycle and construction cost for station investors.
At the core of the unit lies our patented hydraulic reciprocating double-acting compression structure with real-time piston position sensing module. Driven by a motor-powered hydraulic pump set, high-pressure hydraulic oil pushes dual-sided pistons to implement two-stage natural gas compression. A standout advantage of this hydraulic drive design is isolated power and compression chambers: operators can start the compressor at any time without venting high-pressure residual gas inside compression cylinders. This feature slashes power consumption, reduces frequent startup wear and greatly improves overall compression efficiency compared to traditional mechanical linkage compressors.
The gas compression system is split into two independent parallel compression lines that support single-unit standby or simultaneous full-load operation, offering flexible flow matching for stations with variable refueling peak demands. Each compression cylinder adopts vertical three-chamber layout with complete separation between hydraulic oil cavity and natural gas cavity, adopting multi-stage composite sealing without oil lubrication inside gas chambers. Even if minor seal wear occurs, oil and gas will never intermix, fundamentally eliminating natural gas oil contamination risks. This oil-free compression design removes supporting facilities such as lubrication oil pumps, oil-gas separators and sewage tanks, lowering daily consumable expenses and preventing oil residue damage to dispensers, vehicle pipelines and engine systems.
All moving metal parts operate without direct metal friction, and piston linear speed is controlled below 0.2m/s, extending soft sealing service life significantly. Vertical cylinder mounting avoids unilateral abrasion of sealing elements caused by piston gravity, cutting maintenance frequency and long-term service expenditure.
For thermal management, the unit equips three independent water circulation air cooling loops: finned stainless steel radiators cool compressed natural gas after each compression stage; high-efficiency plate-fin aluminum heat exchangers dissipate hydraulic oil heat; antifreeze circulation cools compression cylinder jackets to protect internal sealing components under continuous heavy-load running. The integrated cooling system eliminates overheating shutdown faults during peak refueling hours and stabilizes exhaust temperature within safe working range.
The intelligent PLC control system serves as the operation brain of the whole CNG substation compressor. It continuously monitors real-time operating data including inlet/outlet pressure, hydraulic oil temperature, flow rate, piston travel and flammable gas concentration, supporting automatic fault alarm, emergency stop and historical operation data traceability. Equipped with a touchscreen HMI for local parameter adjustment, the system also supports cloud remote data transmission. Station managers can view equipment running status via mobile phones anytime anywhere under domestic network coverage, realizing remote unmanned management without full-time on-site operators.
Built-in complete CNG gas storage system comes with a total water volume of 2.76m³, composed of medium-pressure and high-pressure steel cylinders at a 2:1 ratio. Each 4130X steel cylinder features 27.5MPa design pressure and 25MPa working pressure, compatible with standard CNG vehicle filling requirements. Matched explosion-proof CNG dispenser adopts high-precision mass flowmeter with built-in temperature compensation sensor, reaching ±1.0 maximum metering error, and meets Exdeia Ga ibmb ll BT4 Gb explosion-proof grade to fit flammable gas station environments.
Full safety protection mechanisms cover the entire skid-mounted unit: high-precision pressure transmitters, LEL combustible gas detectors, oil level & temperature interlock sensors and pressure relief safety valves are pre-installed inside the cabinet. If oil temperature, oil level or system pressure deviates from set thresholds, the system triggers sound-light alarm and auto shutdown instantly. When natural gas concentration hits 5% LEL, exhaust fans activate automatically; at 15% LEL, the whole compressor locks down to eliminate explosion hazards.
The outer cabinet adopts modular weatherproof & noise reduction structure, lined with double-layer sound-absorbing materials to absorb high-frequency noise and block low-frequency vibration transmission. The integrated one-piece roof completely prevents rain leakage, while modular cabinet panels simplify component disassembly, inspection and part replacement during maintenance.
From process flow perspective, the integrated compressor maximizes energy utilization of CNG tank trucks. Tank truck natural gas first directly feeds vehicles via low-pressure pipelines without compressor intervention. When tank pressure drops below vehicle filling pressure, medium-pressure storage cylinders supply gas; once medium-pressure storage is insufficient, high-pressure cylinders take over refueling. Only when high-pressure cylinder pressure falls below the adjustable threshold of 20MPa will the compressor automatically start recharging storage groups. This tiered gas supply logic minimizes compressor startup frequency and cuts daily electricity bills for CNG stations.
Suitable for urban satellite CNG stations, roadside small refueling stations, logistics fleet dedicated gas stations and temporary mobile CNG supply projects, Qingdao Lenado's CNG substation integrated compressor delivers a one-stop high-pressure fluid solution, featuring high automation, zero oil pollution, low maintenance cost, safe unattended running and compact skid-mounted layout.

Main Unit Specification – TYCZ-SJ Series CNG Substation Integrated Compressor

Built-in CNG Dispenser Technical Parameters

Built-in Gas Storage Cylinder Group Parameters

Module Hierarchy Block Diagram

The complete integrated equipment is divided into 6 primary subsystems:
CNG Unloading System
CNG Compression System (split into Hydraulic System, Gas Compression System, Cooling System, Control System)
CNG Storage System
CNG Dispensing System
Safety Protection System
Weatherproof & Noise Reduction Cabinet System

Hydraulic System Circulation Flow Chart

Circulation workflow: Hydraulic Oil Tank → Oil Suction Filter → Oil Pump Motor Unit → Reversing Valve Group → Hydraulic Cylinder → Oil Buffering Tank → Oil Radiator → Return Oil Filter → Back to Oil Tank High-pressure hydraulic oil pushes double-acting compression pistons via directional valve switching; heated hydraulic oil dissipates heat through aluminum radiator before recirculation.

Triple Cooling System Flow Schematic

Three separate heat dissipation pipelines run simultaneously:

Compressed natural gas → Fin stainless steel gas radiator

Hydraulic oil inside tank → Plate-fin aluminum oil cooler

Antifreeze inside compression cylinder water jacket → Aluminum circulation radiator All heat is discharged by forced air cooling fans to stabilize system temperature.

Control Panel Operation Interface

HMI real-time display content: A/B cylinder piston position, inlet/mid/high pressure, hydraulic oil temperature, gas LEL concentration, automatic switching cycle count, fault alarm log, system running time. Supports parameter setting, equipment debugging, cloud data upload and emergency manual control.

Overall Station Business Process Flow

Process logic: CNG Tank Trailer Delivers Natural Gas → Integrated CNG Substation Skid Unit → Direct refueling for sedans & logistics trucks; Real-time data synchronizes to cloud remote management platform for station operators.

Complete Skid-mounted 3D Structural Drawing

Full cabinet internal layout marking all core modules: CNG unloading system, gas compression system, hydraulic power unit, triple cooling assembly, PLC control cabinet, medium/high pressure storage cylinder bank and built-in explosion-proof CNG dispenser, all pre-installed on unified steel skid frame.

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