The Orange County Transportation Authority (OCTA) serves as the County Transportation Commission for Orange County and operates approximately 170 compressed natural gas (CNG) buses out of their Santa Ana Base facility. These buses are refueled using a CNG station co-funded by MSRC Clean Transportation Funding. The station has sufficient capacity to allow OCTA to operate up to 250 CNG buses from their Santa Ana Base facility.
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Construction commenced on June 12, 2006. Installation of the main underground gas pipeline to the CNG station equipment area was completed in August 2006 by the local gas utility. Underground electrical and plumbing was completed in November 2006, as was site preparation work to allow installation of CNG station components.
The station utilizes four (4) 600 horsepower compressors; two were delivered in January 2007 and two in February 2007. Installation of the compressors was followed by installation of the methane detection system, gas dryers, storage vessels, backup generator, and dispenser units. Work was completed in March 2007, including final station inspection, start up, testing, and personnel training.
Maintenance facility modifications included installation of exhaust fans and ductwork, sectional doors, and methane detection systems. This work was completed in July, 2007.
The objective of this project was to construct a new CNG refueling station and implement maintenance facility upgrades at the OCTA Santa Ana Bus Base. A single vendor was selected through a competitive procurement to design, construct, and maintain the new CNG refueling station as well as modify the existing maintenance facility to allow indoor maintenance of CNG buses.
The refueling station was designed and constructed to meet the following design and performance requirements:
- Provide four (4) one hose dispensers for high capacity fast-fill bus refueling up to 3,600 psig;
- Fuel Four (4) buses simultaneously, each with 8,500 standard cubic feet of CNG within 5 minutes of connected fueling time;
- Incorporate one (1) two-hose dispenser for light duty vehicle fast fueling at both 3,600 psig and 3,000 psig;
Incorporate a bus defueling system for returning bus fuel to the suction side of the compressor system.
The CNG refueling station is sized to accomodate substantial growth of the OCTA Santa Ana Base fleet. The station can accomodate the refueling of up to 250 full size transit buses. OCTA currently operates 170 buses out of the Santa Ana Base facility, with 140 buses operating on a daily basis.
One significant issue was encountered early in the operation of the CNG refueling station. Repair of a water main break resulted in the need to subsequently repair a gas main. During gas main repair, water inadvertently entered the line, which impacted the quality of fuel dispensed at the CNG station. The Gas Company subsequently cleaned the 6,200 foot gas pipeline to remove any residual water. The dispensed gas meets quality requirements and no further issues have been encountered.
There have been no operation issues with the CNG refueling station operation or mainenance facility modifications.
The CNG refueling station and modified bus maintenance facility are fully operational. The station currently refuels approximately 140 buses on a daily basis.