Presented by: Cal Macy Project Director Pete Sparks Project Coordinator Natural Gas 101 CNG vs LNG what is the difference?

Presented by:

Cal Macy Project DirectorPete Sparks Project Coordinator

Natural Gas 101CNG vs LNG what is the difference?

Why study natural gas?None of my friends drive one….

• Presented by: – Cal Macy -Long Beach City Cal Macy -Long Beach City

CollegeCollege

ADVANCED TRANSPORTATIONTECHNOLOGY CENTER

ADVANCED TRANSPORTATIONTECHNOLOGY CENTER

Green Port Program

• Ports of LB and LA are going green

ATTE has been teaching “green” before it was a term

What will be the propulsion for the new

Millennium??

NGVFuel Cell

EmergingAlternative

Energies

Diesel Engines

GasolineEngines Hybrid

Cars

DirectInjection

LeanBurn

Common Rail Direct Injection

NGVNatural

Gas Vehicle

FCEVFuel Cell

EV

Series/parallelHybrid

EVElectricVehicles

CNG Hybrid Motor

Heavy-DutyCng/Lng

NGVNatural

Gas Vehicle

•Natural gas is today’s key to a healthier tomorrow

Gaseous/ alcohol based fuels

What will be the propulsion for the new

Millennium??

Range and Reliability are the two biggest challenges for Alternative Fuels

Cost of fuel and availability are the operator’s concerns

Where can I get CNG/LNG for my car or

truck?

•Natural gas is today’s key to a healthier tomorrow

Clean Energy announced plans

to install LNG/CNG fueling stations

across the nation at existing

Pilot/Flying J Truck Stops in 33 states

Phase 1150 new stations

70 in 201280 in 2013$2.79/DGE

LB 1/25/2012

Where can I get

my car or truck serviced?

The ATTE Centers have trained over 5000 fleet technicians from all over the US,

Canada, and Mexico

We can train the next generation of fleet technicians

ADVANCED TRANSPORTATIONTECHNOLOGY CENTERS


ALTERNATIVE FUELS TRAINING

PROGRAMS



•Long Beach was the first Clean City in California•LBCC provided initial CNG & LNG Training for City fleets

•10 ATT Centers were established in 1993



ATTE is a Consortium of 8 Regional Colleges Statewide Providing Alternative Fuels Training since 1995

ATTE is the Statewide Training SolutionWe make the complicated Simple!

Computerized Engine Management

Cummins John Deere Detroit Caterpillar

•We have decades of experience on CEM systems

Electronic Engine Fuel Management Systems

DETROIT DIESEL

DDEC& GFI SYSTEMS

•ATT provided training for the 1996 Olympics in Atlanta

Customized Training Programs:In-Center seminars held in a manufacturer-style

classroom environment with an attached lab

Customized Training Programs:

OEM trainers for Kenworth & Peterbilt LNG drayage trucks

We WROTE the program!!

Live Engine Training on CNG & LNG Demonstrators:

•Hands-on Training with Heavy Duty electronics training engines

•Cummins ISL G CNG/LNG •Cummins/Westport GX LNG •DDEC IV series 50/60G•John Deere

We WROTE the programs!!

Natural Gas Safety

Natural Gas Safety

•We stress safety & regulations

•Cylinder Safety Inspection

Natural Gas Properties

• Odorless– Odorant (Ethyl Mercaptan) added

• Colorless• Lighter than air• Flammability range: 5-15%

– Compare with: diesel 1-6%, propane 2.2-9.5%, hydrogen 4.1-74%

• High auto-ignition temperature – 900-1170°F

• Non-toxic– Displaces oxygen

Natural Gas Vehicle Storage

• Compressed Natural Gas: CNG– Up to 3600- 5000 psi– High pressure storage vessel

• 200:1 STP storage volume

• Liquefied Natural Gas: LNG– Cryogenic temperatures (-250°F) up to 230 psi– Well insulated storage vessel

• 600:1 STP storage volume

Compressed Natural Gas

Considerations• Fueling infrastructure

– Strong

• Engine type– SI or dual fuel

• Vehicle range• Cylinder quantity and configuration• Fast fill or slow fill

Compressed Natural Gas

• High pressure gas cylinders– Flexible sizes and configurations– Light weight (relative to LNG tanks)

• Safety– Extreme high pressures– Frequent CNG system inspections

Cylinder Type 1

• All steel or aluminum construction

• 100% pressure is held by the metal

• Vulnerable to rust and corrosion

Type 1 Cascade

Cylinder Type 2

• Hoop-wrapped aluminum or steel

• 55% pressure is held by metal, 45% is held by the wrap

• Vulnerable to corrosion and wrap damage

Cylinder Type 3

•Fully wrapped aluminum

•80% pressure is held by the wrap, 20% is held by the metal

•Vulnerable to cuts and abrasion

Cylinder Type 4

• All composite cylinder with a plastic liner

• 100% pressure is held by composite wrap

• Liner sealed to metal domes used for valve threads

• Light weight, vulnerable to impact & cuts

Liquefied Natural Gas

Considerations• Fueling infrastructure

– In development– Mobile units available

• Engine type– HPDI, SI or duel fuel

• Vehicle range• LNG tank weight and size• Vehicle utilization should be frequent

Liquefied Natural Gas

• Cryogenic storage tank

• Somewhat limited configurations and sizes

• Safety– Extreme cold temperature

• Down to - 250°F

– Pressures up to 230 psi– Robust design

Liquefied Natural Gas Tanks

• Stainless steel construction

• Vacuum insulation

• Specialized valves and components

• Sizing typically 50- 150 gallons

• Two distinct types– Integrated LNG pump and vaporizer– Pressure flow with external vaporizer


• Integrated LNG pump and vaporizer– Utilization of any temperature LNG– Up to 5000 psi CNG output

• Electronically regulated

– HPDI equipped engines


• Pressure flow with external vaporizer– Requires utilization of “warm” LNG– Up to tank pressure output

• < 230 psi

• Mechanical regulation

– SI or dual fuel equipped engines

Natural Gas Engines

• Westport HD15

• CWI ISL G

• CWI ISX12 G

• Other engines/ options– John Deere– Detroit Diesel– CAP dual fuel

Westport HD15 Engine

• 15 liter compression ignition• Direct injection diesel pilot• Up to 475 HP, 1750 lb-ft torque• Active emissions aftertreatment system

CWI ISL G Engine

• 8.9 liter spark ignition• Mass air/ gas electronic fuel injection• Up to 320 HP, 1000 lb-ft torque• Passive three way catalyst emissions system

CWI ISX12 G Engine

• 12 liter spark ignition• Mass air/ gas electronic fuel injection• Up to 400 HP, 1450 lb-ft torque• Passive three way catalyst emissions system

How does Natural Gas How does Natural Gas work in the Engine?work in the Engine?

Operating Pressures and Operating Pressures and SafetySafety

• Non-toxicNon-toxic• Lighter than airLighter than air• CNG can displace oxygenCNG can displace oxygen• CNG highly flammable?CNG highly flammable?

– Must be contained to be dangerousMust be contained to be dangerous– Window of flammability very narrowWindow of flammability very narrow

• No open flames in the shopNo open flames in the shop• Safest fuel of all other fuelsSafest fuel of all other fuels• Pressure in system must be respectedPressure in system must be respected

Major Major Components Components

of a of a Compressed Compressed Natural Gas Natural Gas

SystemSystem

Fill Valve and Coalescent FilterFill Valve and Coalescent Filter

• NGV1 Fuel fill device needs to match pressure of cylinderMust have dust cap installed after filling vehicleCoalescing filter can be on fill inlet or supply line

One-Way Check ValveOne-Way Check Valve

•Allows fuel to flow in one direction onlyUsually on fill line to prevent leakage in case of drive-away

Fuel Storage Cylinders Fuel Storage Cylinders

•High pressure storage 4 different types availableSeveral pressures availableShould all be matching pressure

•3600 PSI

•Type 2

•3000 PSI

•Type 4

Cylinder Shut-Off Cylinder Shut-Off Valve Valve

Caution: pressure may still be present!

•Isolates cylinder for servicing

•Special tool needed to open dead electronic valves•Destroys seals in valve

Pressure Relief Device Pressure Relief Device (PRD)(PRD)

•Releases in case of excessive heat or pressureMounted on cylinder IN DIRECT PRESSUREOne-time failure--- vented to outside of vehicleCannot be removed and reused on another cylinderSpecial design for type 4—all composite cylinders

Manual Shut-Off ValveManual Shut-Off Valve(Quarter Turn)(Quarter Turn)

•Shuts off fuel to engine compartmentEmergency shut-off accessible from outside

Stainless Steel Fuel Stainless Steel Fuel LinesLines

•Seamless Stainless Steel LinesFittings and lines must be rated to withstand3 times their system pressureRelief loops to prevent vibration failuresSome vehicles use flexible lines with stainless weave

Pressure Pressure Regulator(s)Regulator(s)

Reduces cylinder pressure to system operating pressureMay have two regulators to drop pressure in stages Pressure typically 120 psi or less depending upon system

Shut off Valves (Lock-Offs)Shut off Valves (Lock-Offs)

Prevents fuel flow unless engine RPM is presentPrevents fuel flow unless engine RPM is present

• Controlled by PCMControlled by PCM

Introduces fuel to intake air stream

High pressure direct injection

Westport GX injector

Cummins ISL G Fuel Control Valve

Fuel Delivery to EngineFuel Delivery to Engine

Powerplant & Fueling Options

• Cummins/Westport ISL-G Natural Gas Engine

• Cummins/Westport ISX12-G Natural Gas Engine

• Westport GX 15 liter Diesel/Natural Gas Hybrid Engine


ISL-G 8.9L Natural Gas Engine


Cummins/Westport ISL-G•Type - 4-cycle, spark-ignited, inline 6-cylinder, turbocharged

•8.9 Liter, coil on plug ignition (300v primary)

•Compressed Natural Gas (CNG – 3600psi) or Liquefied Natural Gas (LNG)

•Dedicated & Optimized for natural gas fuel (105 parameters)

•Meets EPA and CARB 2010 emission requirements

•EGR and Catalyst (stoiciometric)

•Advertised Horsepower 250–320 hp

•Peak Torque 660–1,000 lb-ft

•PM’s differ from diesel


ISX12-G 11.9L Natural Gas Engine


Cummins/Westport ISX12-G•Type - 4-cycle, spark-ignited, inline 6-cylinder, turbocharged

•11.9 Liter Compressed Natural Gas (CNG – 3600psi) or Liquefied Natural Gas (LNG)

•Dedicated & Optimized for natural gas fuel (stoiciometric)


•Advertised Horsepower 330 – 400 hp

•Peak Torque 1150 – 1450 lb-ft

•First time available engine braking option

•Available early 2013

•Common-rail•diesel•fuel pump

•Hydraulic•pump (drives LNG Pump)

•Fuel conditioningmodule

•Control units•(firewall mounted)

•LNG tank and pump•(chassis mounted)

•Fuel injectors•(under valve cover)


Westport GX 15 liter HPDI Diesel/NG Engine


Westport GX HPDI Diesel/NG Hybrid•Type - 4-cycle, pilot ignition, inline 6-cylinder, turbocharged

•15 Liter

•Proprietary Liquefied Natural Gas (LNG) design

•Dedicated & Optimized for natural gas fuel


•Advertised Horsepower 400 – 475 hp

•Peak Torque 1450 – 1750 lb-ft

•Proven reliability since 2006

•Requires PM trap & SCR (urea) injection for EPA/CARB 2010

What Regulations Should I Be Training my students to be aware of?

NFPA 52NFPA 52

-Covers installations of cylinders and components -Covers installations of cylinders and components CHP Title 13 CHP Title 13

-Covers state certification of installations and vehicles-Covers state certification of installations and vehicles CGA 6.4 CGA 6.4

-Covers visual inspection and qualifications of inspectors-Covers visual inspection and qualifications of inspectors ANSI/NGV-2/FMVSS 304 ANSI/NGV-2/FMVSS 304

-Covers design, construction and testing of new cylinders-Covers design, construction and testing of new cylinders ManufactureManufacture’’s Printed Guidelines s Printed Guidelines

-Covers i-Covers inspection, repair and condemnationnspection, repair and condemnation

Regulations & Guidelines for CNG & LNG Regulations & Guidelines for CNG & LNG Vehicle Operation and MaintenanceVehicle Operation and Maintenance

NFPA 52 NFPA 52 Vehicle Installation Vehicle Installation

GuidelinesGuidelines

Covers proper installation and Covers proper installation and system safetysystem safety Hard copy or downloadableHard copy or downloadable ““Industry standardIndustry standard”” California makes it a lawCalifornia makes it a law OEMOEM’’s adhere to it s adhere to it Fire Dept. recognizedFire Dept. recognized Updated every few yearsUpdated every few years

- - www.nfpa.org

NFPA 52 SectionsNFPA 52 Sections1. Administration2. Referenced Publications3. Definitions4. General CNG Requirements

& Equipment Qualifications5. General GH2 Requirements &

Equipment Qualifications6. CNG Engine Fuel Systems7. Service & Maintenance of

GH2 Engine Fuels Systems8. CNG Compression, Gas

Processing, Storage, and Dispensing Systems

9. GH2 Compression, Gas processing, Storage, Dispensing

10. CNG Residential Fueling Facilities

11. LNG Engine Fuel Systems12. LNG Fueling Facilities13. LH2 Fueling Facilities14. LNG Fire Protection15. Installation Requirements for

ASME Tanks for LNG16. LNG and CNG on Commercial

Marine Vessels and Pleasure Craft

CGA 6.4CGA 6.4Inspection Inspection

ProceduresProcedures• Inspection procedures and damage assessment• Criteria for the acceptance or rejection of containers• Qualifications of inspectors

• Recommended minimum: inspection every 3 or 36,000 miles for life of container

• Defines 3 levels of damage and appropriate

actions for each

• Provides guidance on what the inspector must

look for and how to make service/disposal

determinations

• Manufacturer’s instructions take precedence

•Proper documentation and labels required

• CGA 6.4CGA 6.4Inspection ProceduresInspection Procedures

Compressed Gas Association, Inc.Compressed Gas Association, Inc. 4221 Walney Road, 54221 Walney Road, 5thth Floor Floor Chantilly, VA 20151Chantilly, VA 20151703-788-2700703-788-2700www.cganet.comHard copy or downloadableHard copy or downloadable

• CGA 6.4CGA 6.4Inspection ProceduresInspection Procedures

In addition, CGA 6.4 will provide what you need to know about:

• Brackets, straps, and mounting systems as recommended by the

container manufacturer

• Labeling information

• Appropriate inspection equipment

Facility ConsiderationsFacility Considerations

•NO Open flames or spark emitting equipment•Sealed lighting•Ventilation requirements •Methane detectors and alarms

Local laws and regulations vary

Each facility should obtain an Engineering survey by a company specializing in CNG facilities to determine what is needed at that location

Facility ConsiderationsFacility Considerations

•Local laws and regulations vary•Each facility should obtain an Engineering survey by a company specializing in CNG facilities to determine what is needed at that location

Regulations & Guidelines for CNG & LNG Regulations & Guidelines for CNG & LNG Vehicle Operation and MaintenanceVehicle Operation and Maintenance

• Know the codes• Consult the experts

Questions? Contact one of the Advanced Transportation Technology & Energy Centers statewide

THANK YOU

Documents

Presented by: Cal Macy Project Director Pete Sparks Project Coordinator Natural Gas 101 CNG vs LNG what is the difference?