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

3. Why study natural gas? None of my friends drive one…. Presented by: –Cal Macy -Long Beach City College ADVANCED TRANSPORTATION TECHNOLOGY CENTER

4. Green Port Program Ports of LB and LA are going green ATTE has been teaching “green” before it was a term

5. What will be the propulsion for the new Millennium?? NGV Fuel Cell Emerging Alternative Energies Diesel Engines Gasoline Engines Hybrid Cars Direct Injection Lean Burn Common Rail Direct Injection NGV Natural Gas Vehicle FCEV Fuel Cell EV Series/ parallel Hybrid EV Electric Vehicles CNG Hybrid Motor Heavy-Duty Cng/Lng NGV Natural Gas Vehicle Natural gas is today’s key to a healthier tomorrow Gaseous/ alcohol based fuels

6. 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

7. 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 1 150 new stations 70 in 2012 80 in 2013 $2.79/DGE LB 1/25/2012

8. 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

9. ADVANCED TRANSPORTATION TECHNOLOGY CENTERS ALTERNATIVE FUELS TRAINING PROGRAMS

10. ADVANCED TRANSPORTATION TECHNOLOGY CENTERS 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

11. ADVANCED TRANSPORTATION TECHNOLOGY CENTERS ATTE is a Consortium of 8 Regional Colleges Statewide Providing Alternative Fuels Training since 1995 ATTE is the Statewide Training Solution We make the complicated Simple!

12. Computerized Engine Management Cummins John Deere Detroit Caterpillar We have decades of experience on CEM systems

13. Electronic Engine Fuel Management Systems DETROIT DIESEL DDEC& GFI SYSTEMS ATT provided training for the 1996 Olympics in Atlanta

14. Customized Training Programs: In-Center seminars held in a manufacturer-style classroom environment with an attached lab

15. Customized Training Programs: OEM trainers for Kenworth & Peterbilt LNG drayage trucks We WROTE the program!!

16. 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!!

17. Natural Gas Safety We stress safety & regulations Cylinder Safety Inspection

18. 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

19. 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

20. Compressed Natural Gas Considerations Fueling infrastructure –Strong Engine type –SI or dual fuel Vehicle range Cylinder quantity and configuration Fast fill or slow fill

21. 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

22. Cylinder Type 1 All steel or aluminum construction 100% pressure is held by the metal Vulnerable to rust and corrosion Type 1 Cascade

23. 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

24. Cylinder Type 3 Fully wrapped aluminum 80% pressure is held by the wrap, 20% is held by the metal Vulnerable to cuts and abrasion

25. 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

26. 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

27. 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

28. 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

29. Liquefied Natural Gas Tanks Integrated LNG pump and vaporizer –Utilization of any temperature LNG –Up to 5000 psi CNG output Electronically regulated –HPDI equipped engines

30. Liquefied Natural Gas Tanks 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

31. Natural Gas Engines Westport HD15 CWI ISL G CWI ISX12 G Other engines/ options –John Deere –Detroit Diesel –CAP dual fuel

32. Westport HD15 Engine 15 liter compression ignition Direct injection diesel pilot Up to 475 HP, 1750 lb-ft torque Active emissions aftertreatment system

33. 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

34. 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

35. How does Natural Gas work in the Engine?

36. Operating Pressures and Safety 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 dangerous –Window 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

37. Major Components of a Compressed Natural Gas System

38. Fill Valve and Coalescent Filter NGV1 Fuel fill device needs to match pressure of cylinder  Must have dust cap installed after filling vehicle  Coalescing filter can be on fill inlet or supply line

39. One-Way Check Valve Allows fuel to flow in one direction only  Usually on fill line to prevent leakage in case of drive-away

40. Fuel Storage Cylinders High pressure storage  4 different types available  Several pressures available  Should all be matching pressure 3600 PSI Type 2 3000 PSI Type 4

41. Cylinder Shut-Off Valve  Caution: pressure may still be present! Isolates cylinder for servicing Special tool needed to open dead electronic valves Destroys seals in valve

42. Pressure Relief Device (PRD) Releases in case of excessive heat or pressure  Mounted on cylinder IN DIRECT PRESSURE  One-time failure--- vented to outside of vehicle  Cannot be removed and reused on another cylinder  Special design for type 4—all composite cylinders

43. Manual Shut-Off Valve (Quarter Turn) Shuts off fuel to engine compartment  Emergency shut-off accessible from outside

44. Stainless Steel Fuel Lines Seamless Stainless Steel Lines  Fittings and lines must be rated to withstand  3 times their system pressure  Relief loops to prevent vibration failures  Some vehicles use flexible lines with stainless weave

45. Pressure Regulator(s)  Reduces cylinder pressure to system operating pressure  May have two regulators to drop pressure in stages  Pressure typically 120 psi or less depending upon system

46. Shut off Valves (Lock-Offs) Prevents fuel flow unless engine RPM is present Controlled by PCMControlled by PCM

47. Introduces fuel to intake air stream High pressure direct injection Westport GX injector Cummins ISL G Fuel Control Valve Fuel Delivery to Engine

48. 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

49. Powerplant & Fueling Options ISL-G 8.9L Natural Gas Engine

50. Powerplant & Fueling Options 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

51. Powerplant & Fueling Options ISX12-G 11.9L Natural Gas Engine

52. Powerplant & Fueling Options 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) Meets EPA and CARB 2010 emission requirements Advertised Horsepower 330 – 400 hp Peak Torque 1150 – 1450 lb-ft First time available engine braking option Available early 2013

53. Common-rail diesel fuel pump Hydraulic pump (drives LNG Pump) Fuel conditioning module Control units ( firewall mounted) LNG tank and pump (chassis mounted) Fuel injectors (under valve cover) Powerplant & Fueling Options Westport GX 15 liter HPDI Diesel/NG Engine

54. Powerplant & Fueling Options 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 Meets EPA and CARB 2010 emission requirements 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

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

56.  NFPA 52 -Covers installations of cylinders and components -Covers installations of cylinders and components  CHP Title 13 -Covers state certification of installations and vehicles -Covers state certification of installations and vehicles  CGA 6.4 -Covers visual inspection and qualifications of inspectors -Covers visual inspection and qualifications of inspectors  ANSI/NGV-2/FMVSS 304 -Covers design, construction and testing of new cylinders -Covers design, construction and testing of new cylinders  Manufacture’s Printed Guidelines -Covers inspection, repair and condemnation -Covers inspection, repair and condemnation Regulations & Guidelines for CNG & LNG Vehicle Operation and Maintenance Regulations & Guidelines for CNG & LNG Vehicle Operation and Maintenance

57. NFPA 52 Vehicle Installation Guidelines  Covers proper installation and system safety system safety  Hard copy or downloadable  “Industry standard”  California makes it a law  OEM’s adhere to it  Fire Dept. recognized  Updated every few years - - www.nfpa.org

58. NFPA 52 Sections 1.Administration 2.Referenced Publications 3.Definitions 4.General CNG Requirements & Equipment Qualifications 5.General GH2 Requirements & Equipment Qualifications 6.CNG Engine Fuel Systems 7.Service & Maintenance of GH2 Engine Fuels Systems 8.CNG Compression, Gas Processing, Storage, and Dispensing Systems 9.GH2 Compression, Gas processing, Storage, Dispensing 10.CNG Residential Fueling Facilities 11.LNG Engine Fuel Systems 12.LNG Fueling Facilities 13.LH2 Fueling Facilities 14.LNG Fire Protection 15.Installation Requirements for ASME Tanks for LNG 16.LNG and CNG on Commercial Marine Vessels and Pleasure Craft

59. CGA 6.4 Inspection Procedures CGA 6.4 Inspection Procedures Inspection procedures and damage assessment Criteria for the acceptance or rejection of containers Qualifications of inspectors

60. 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 6.4 Inspection Procedures CGA 6.4 Inspection Procedures

61. Compressed Gas Association, Inc. 4221 Walney Road, 5 th Floor 4221 Walney Road, 5 th Floor Chantilly, VA 20151 Chantilly, VA 20151703-788-2700 www.cganet.com Hard copy or downloadable CGA 6.4 Inspection Procedures CGA 6.4 Inspection 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

62. Facility 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

63. Facility 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

64. Regulations & Guidelines for CNG & LNG Vehicle Operation and Maintenance Regulations & Guidelines for CNG & LNG Vehicle Operation and Maintenance Know the codes Consult the experts Questions? Contact one of the Advanced Transportation Technology & Energy Centers statewide THANK YOU