Commissioning a CNG station in Rajkot, from tubing to handover

Project overview

A CNG station is only as reliable as the integration between its critical systems. Even when every equipment package is supplied and installed correctly, the high-pressure tubing, interconnections, fittings, panel tubing and commissioning decide whether the station runs safely and reliably.

Urjika executed site commissioning and high-pressure tubing works for CNG station projects. At Rajkot, Gujarat, Urjika deployed dedicated technical manpower for on-site commissioning and system integration, and the station is now operational and running. Urjika also completed high-pressure tubing works for a CNG station at Gwalior.

The challenge

A CNG station is a set of interconnected systems working at high pressure. Each one had to be connected with the right fittings and routing to make a single, functional station:

• CNG compressor
• LCV filling system
• CNG dispenser
• High-pressure and underground tubing
• Panel tubing, instrumentation and associated connections
• Fittings and accessories

Our approach

Urjika deployed dedicated technical manpower at the Rajkot site. Mr. Mohan Lal of Urjika’s site team carried out the field work — physically connecting and integrating the station’s major systems, and supporting the final commissioning and handover.

The objective was straightforward: connect, test, commission, verify, hand over.

Scope of work

1. 01

   Compressor connection

   The CNG compressor was connected to the station’s gas system with high-pressure tubing and fittings, with attention to routing and fitting installation.

2. 02

   LCV connection

   The LCV filling system was tied into the station’s high-pressure gas network.

3. 03

   Dispenser connection

   The dispenser was connected to the gas supply lines so it receives gas from the upstream system as part of the complete station.

4. 04

   Underground tubing

   Underground connections between the equipment and station infrastructure, kept organised and functional.

5. 05

   Panel tubing

   Panel-side tubing and fittings connected to the relevant equipment and instrumentation.

6. 06

   Fittings & connections

   Fitting selection and installation, equipment interconnections, tubing routing and final connection verification.

7. 07

   Testing & commissioning

   The connected systems were checked to verify that the equipment works as intended and the station is ready to operate.

8. 08

   Final handover

   Equipment was checked for proper functioning before the work was handed over to the customer’s site team.

Outcome

The Rajkot CNG station was commissioned with Urjika’s site execution and technical support, and is operational and running.

At Gwalior, Urjika executed the site-level high-pressure tubing needed for station integration and commissioning — further experience in high-pressure tubing, equipment interconnection, fitting installation and commissioning support.