Compact & Efficient: Transforming LNG Bunkering Operations with Ingersoll Rand Plug-and-Play Compressed Air Solutions

When a leading global EPC (Engineering, Procurement, and Construction) contractor from Spain, specializing in industrial facilities, needed a reliable and efficient compressed air system, they turned to Ingersoll Rand for assistance.

The challenge was clear: adapt the end-user company’s port terminal in southern Spain for bunkering, enabling the supply of liquefied natural gas (LNG) to ships as part of the company’s energy transition and decarbonization strategy.

The terminal achieved a storage capacity of approximately 4,080 m3 and managed an annual energy volume of 1,100 GWh. With this capacity, it has become the leading LNG bunkering port station in Spain.

As a trusted global provider of pressure equipment for a wide range of industries, and with extensive expertise in delivering engineered-to-order solutions, Ingersoll Rand provided the customer with an optimal compressed air system designed to meet their instrumentation air demands: a critical utility for all system instrumentation and for providing plant air.

The Ingersoll Rand Engineered Systems and Services (ESS) team successfully overcame several challenges when designing and implementing a compressed air system for this LNG supply plant.

One of the primary challenges was the absence of a covered area to protect the system against aggressive environmental conditions, which required the development of an outdoor solution. To address this, the team engineered a robust package capable of enduring exposure to the elements, including harsh marine conditions. Given the system's proximity to the sea and frequent wave activity, it was regularly exposed to saltwater. To combat corrosion, the entire package was meticulously coated with specialized anti-corrosion paint, ensuring durability and reliability in the demanding environment.

Additionally, the project required a system design that adhered to strict dimensional constraints, ensuring a compact footprint without compromising performance.

This innovative design and engineering solution not only met the challenging environmental requirements but also exemplified Ingersoll Rand's commitment to delivering tailored systems that excel in extreme conditions.

Our specialized team of rotary screw compressor experts successfully delivered a comprehensive solution tailored to meet the customer’s instrument air supply requirements. This turnkey package included not only a complete air compressor system but also full project management services—covering documentation, on-site commissioning, and long-term aftermarket support.

To meet the facility’s high compressed air demand, the solution featured:

• Two oil-flooded rotary screw compressors
• Two heatless desiccant dryers
• Air receivers
• All integrated on a common skid with piping, control systems, electrical installation, and a fully redundant PLC control system, including automated hot air duct louvers
• Complete aftermarket support, including genuine spare parts and maintenance contracts

Each unit was precisely assembled and rigorously tested at state-of-the-art manufacturing facilities to ensure peak performance. After testing, the systems were carefully disassembled for transport and expertly reassembled on-site.

Our customer reaped significant benefits from a fully customized solution meticulously designed to address their complex engineering and operational requirements. This tailored approach ensured exceptional value, reliability, and long-lasting performance.

The implementation of the instrument air packages introduced a compact and highly efficient compressed air system that has been operating flawlessly since 2023. Engineered with a minimal footprint of just 9 m x 2.4 m, the plug & play solution required minimal integration effort, with only a single power feed needed to begin producing compressed air.

To maximize operational simplicity, we developed a streamlined package control system, equipped with a centralized control box for signal collection and communication. This design provided the customer with a user-friendly and highly dependable system, perfectly aligned with their specific needs and expectations.

Our dedication extended far beyond system delivery. Throughout the project lifecycle, we offered comprehensive support, including detailed documentation, rigorous quality procedures, and hands-on assistance at every stage. Ever since successful commissioning, the plant has continued to operate seamlessly, supported by our ongoing commitment to performance optimization. This includes providing spare parts and dispatching technicians for preventive maintenance as needed.

This case exemplifies our ability to deliver cutting-edge solutions that combine technical excellence with unmatched service. By prioritizing reliability and customer satisfaction, we have ensured long-term operational success and strengthened our reputation as a trusted partner.

The successful delivery of the instrumentation air packages not only exceeded expectations but also significantly strengthened our relationship with the customer. This fruitful collaboration opened doors to additional projects, further solidifying our partnership.

The customer was highly satisfied not only with the customized solution we provided, which was tailored to operate under extreme environmental conditions within the required space, but also with the comprehensive support they received throughout all phases of the project. Our team ensured they were equipped with all the necessary documentation to meet their needs effectively.

Reach out to our sales team today to learn more about our customized compressor solutions!