Sinopec Gas Station EV Charging: Deploying 100+ Sites Across China's Highway Network
When Sinopec, the world's second-largest gas station operator with over 30,000 stations globally, decided to electrify its highway network, they needed a partner who could deliver at scale without compromising on safety or reliability. FBK POWER was selected to supply DC fast charging equipment for over 100 sites along China's major highway corridors. This case study explains the project scope, the technical challenges, and the outcomes.
Project Overview
Sinopec's electrification strategy targets highway corridors connecting major cities, where long-distance EV drivers need reliable fast charging. The project required:
- 100+ charging sites along designated Alternative Fuel Corridors
- Dual-port 120kW DC fast chargers at each location
- 97% uptime guarantee with 24/7 remote monitoring
- 6-month deployment timeline from contract to commissioning
Technical Requirements
Power and Connector Standards
Each site was equipped with FBK POWER's Split-Type DC Charging Cabinet, configured for:
| Specification | Requirement | FBK Solution |
|---|---|---|
| Output Power | 120 kW per site | 2 x 60 kW modules, hot-swappable |
| Voltage Range | 200-750 VDC | Full-range output |
| Connectors | CCS2 + GB/T | Dual-cable configuration |
| Protection | IP54 minimum | IP54 with optional IP65 |
| Communication | OCPP 1.6 | Native OCPP with JSON over TLS |
Grid Integration Challenges
Highway gas stations typically have limited grid capacity. FBK POWER's engineering team conducted site surveys and designed custom power distribution solutions:
- Transformer upgrades at 35% of sites
- Load management algorithms to balance EV charging with station operations
- Battery buffering at 12 high-traffic sites to reduce peak demand charges
Deployment Timeline
| Phase | Duration | Activities |
|---|---|---|
| Site Survey | Month 1-2 | Grid assessment, civil work planning |
| Manufacturing | Month 2-4 | Mass production at Wenzhou factory |
| Installation | Month 4-5 | On-site commissioning, testing |
| Go-Live | Month 6 | Operator training, monitoring setup |
Results and Impact
After 12 months of operation, the network has delivered:
- 97.3% uptime across all sites (exceeding 97% guarantee)
- 450,000+ charging sessions completed
- Average session rating 4.7/5.0 from driver app feedback
- $2.1M revenue generated for Sinopec in first year
Key Success Factors
- Vertically integrated manufacturing enabled rapid scaling without supply chain delays
- Modular power architecture allowed hot-swap maintenance without site downtime
- Remote diagnostics via OCPP backend reduced mean-time-to-repair by 60%
- Local service partnerships ensured 4-hour response time for critical failures
Lessons for Highway Charging Deployments
- Start with grid capacity assessment before hardware selection
- Design for 150% of projected demand to accommodate growth
- Invest in remote monitoring infrastructure from day one
- Plan maintenance windows during low-traffic periods (2-6 AM)
Next Steps
Sinopec and FBK POWER are expanding the partnership to 300+ sites by 2027, including urban locations and rural highway corridors. The next phase will introduce 480kW high-power charging for heavy-duty electric trucks.
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