inspection guidelines for cng & lpg vehicle conversions

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CNG and LPG Vehicle Purchasing Inspection Guidelines > January 2014

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This Clean Cities webinar is an overview of the processes of converting a vehicle to CNG & LPG and the need to use a qualified installer. We had speakers from the Gas Technology Institute in Illinois who will gave an overview of the guidelines to inspect CNG and LPG vehicle conversions. Also, American Power Group, ROUSH CleanTech, and Barnes, Inc. covererd the conversion kits and processes of installing them.

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Page 1: Inspection Guidelines for CNG & LPG Vehicle Conversions

CNG and LPG Vehicle Purchasing Inspection Guidelines

> January 2014

Page 2: Inspection Guidelines for CNG & LPG Vehicle Conversions

22

Statement of Purpose

Agenda

• Consumer expectations for CNG and LPG vehicle purchases

• Inspection requirements for CNG and LPG vehicles

• Finding a qualified individual to conduct safety inspections

• Training for inspectors

• Inspection checklist

Page 3: Inspection Guidelines for CNG & LPG Vehicle Conversions

33

Converted CNG Vehicle Purchase

Guidance: Do some research.

1. US EPA and CARB certified conversion kits and engine platforms are allowable under current federal regulation.• NGVA List:

http://www.ngvc.org/pdfs/availablevehiclesandconversions_130920_final.pdf

• EPA Website: Certified Clean Alternative Fuel Conversion Systems http://www.epa.gov/otaq/consumer/fuels/altfuels/documents/certified-conversions.xls

2. Converters need to be approved by kit manufacturer. It is preferred to confirm converter has ASE/CSA qualified technicians installing conversion kits.

Page 4: Inspection Guidelines for CNG & LPG Vehicle Conversions

44

Converted CNG Vehicle Purchase (Continued)

Guidance: Do some research.

3. Expand knowledge base. Use the following documents to educate yourself in the basics.• “Have Your Vehicle Converted to Compressed Natural

Gas- Safety”, Clean Vehicle Education Foundation (http://www.cleanvehicle.org/committee/technical/PDFs/Convert_Your_Vehicle_Safely_Final.pdf).

• “Fact Sheet: Converting Light Duty Vehicles to Natural Gas”, NGVAmerica (http://www.ngvc.org/pdfs/FAQs_Converting_to_NGVs.pdf.)

4. Determine fueling logistics. Want to identify and secure at lease two fueling options.

Page 5: Inspection Guidelines for CNG & LPG Vehicle Conversions

55

CNG Vehicle Inspection

Guidance: Know the facts.

1. ANSI NGV 2 (fuel tank spec) requires an inspection of the fuel tank every 3 years.

2. TP-304-03 FMVSS (CNG Fuel Container Integrity), National Highway Traffic Safety Administration requires additional “or 36,000 miles” for tank inspection.

3. NFPA 52 requires that a tank is inspected ─ After an accident or fire─ Before it is reinstalled in a vehicle

Page 6: Inspection Guidelines for CNG & LPG Vehicle Conversions

66

CNG Vehicle Inspection (Continued)

Guidance: Know the facts.

4. The Compressed Gas Association (CGA) defines a qualified inspector as:• 2 years experience conducting inspections• Supervision by person with 2 years experience conducting

inspections• Approved by fuel cylinder manufacturer• Certification from original equipment manufacturer

through training center• Certification from nationally recognized organization

e.g. CSA • Certification as inspector by Authority Having Jurisdiction

Page 7: Inspection Guidelines for CNG & LPG Vehicle Conversions

77

CNG Vehicle Inspection (Continued)

Finding an certified inspector:• CSA provides certification for CNG fuel system inspection

which includes all major components and tanks.• CSA offers a list of qualified and certified fuel system

inspectors on their website.

http://www.csagroup.org/us/en/services/education-and-training/personnel-certification/people-search

CNG Fuel System Inspection Training• CVEF List

(http://www.cleanvehicle.org/technology/cylinder.shtml)

Page 8: Inspection Guidelines for CNG & LPG Vehicle Conversions

88

Municipal/Licensing Entity CNG Vehicle Inspection

• GTI has prepared a template checklist for inspection of CNG vehicles

• Checklist is available and will be accessible on CACC, WICC, and SSCC websites

• Checklist is NOT a substitute for certified vehicle inspections

Page 10: Inspection Guidelines for CNG & LPG Vehicle Conversions

1010

LPG Vehicle Purchase (Continued)

Guidance: Do some research.

2. Confirm converter has trained technicians installing conversion kits. (NFPA 58)• Propane autogas technician course and training (PERC

partnership with National Alternative Fuels Training Consortium)

• OEM approved/trained installations

3. Expand knowledge base. Use the following website to educate yourself in the basics. Propane Education and Research Council (PERC) website is useful.• www.autogasusa.org

Page 11: Inspection Guidelines for CNG & LPG Vehicle Conversions

1111

LPG Vehicle Purchase (Continued)

Guidance: Do some research.

4. Determine fueling logistics. You may want to secure at lease two fueling options.

Page 12: Inspection Guidelines for CNG & LPG Vehicle Conversions

1212

LPG Vehicle Inspection

Guidance: Know the facts.

1. Propane containers are certified by ASME or DOT • DOT cylinders are mainly used for industrial and off

road applications such as forklifts, mowers, etc.

2. NFPA 58 states fuel containers have to be requalified per Compressed Gas Association inspection criteria. Good practice to include vehicles involved in fire and/or auto accidents.

3. Follow OEM specifications for inspections/training.

4. NFPA 58 requires vehicle fuel system to be leak free prior to garage storage or service.

Page 13: Inspection Guidelines for CNG & LPG Vehicle Conversions

1313

Municipal/Licensing Entity LPG Vehicle Inspection

• GTI is preparing a template checklist for inspection of LPG vehicles

• Checklist will be accessible on CACC, WICC, and SSCC websites

• Checklist is NOT a substitute for experienced vehicle inspections

Page 14: Inspection Guidelines for CNG & LPG Vehicle Conversions

1414

WI State Vehicle Inspection

1. The Wisconsin Department of Transportation’s (WDOT) State Patrol conducts safety inspections on the following vehicle types, ambulances, motor buses, school buses, human service vehicles, farm vehicles, salvage titled vehicles, and homemade/reconstructed vehicles.

2. WDOT participates in Motor Carrier Safety Assistance Program (MCSAP), which federally mandates a safety audit which includes vehicle inspection for vehicles transporting goods and passengers in interstate commerce.

Page 15: Inspection Guidelines for CNG & LPG Vehicle Conversions

1515

Acknowledgement of Support

Page 16: Inspection Guidelines for CNG & LPG Vehicle Conversions

1616

Questions?

Thank you for your time.

Page 17: Inspection Guidelines for CNG & LPG Vehicle Conversions

Phillip MaileyBusiness ManagerNorth Central [email protected]

Powered by:

PROPANE AUTOGAS: A CLEAR CHOICE

Page 18: Inspection Guidelines for CNG & LPG Vehicle Conversions

ABOUT US

Company Background & History

Page 19: Inspection Guidelines for CNG & LPG Vehicle Conversions

Roush Fenway Racing

Page 20: Inspection Guidelines for CNG & LPG Vehicle Conversions

Enterprise Brand Portfolio

Roush Fenway RacingDominant NASCAR Sprint Cup racing team.

ROUSH PerformanceIndustry leading high performance vehicles.

ROUSH Life SciencesMedical equipment design, manufacturing and engineering.

ROUSH IndustriesOEM manufacturing, engineering, prototyping and design.

Page 21: Inspection Guidelines for CNG & LPG Vehicle Conversions

Wheel of Capability

Page 22: Inspection Guidelines for CNG & LPG Vehicle Conversions

Propane Autogas– Over 4,000 vehicles sold.– Service, warranty, sales infrastructure in place.

Compressed Natural Gas (CNG)• Design of fuel system.• Calibration.

Electric– Over 16,000 recharging stations built.– Blink ECOtality contract with U.S. DOE.

Hydrogen• 207.297 MPH (world land-speed record.)

Alt. Fuel Experience

Page 23: Inspection Guidelines for CNG & LPG Vehicle Conversions

ROUSH CleanTech

• Founded in 2010.

• Dedicated to developing quality alternative fuel solutions.

• Propane autogas focus.

• EPA and CARB certification ability.

• Platform customization to suit customer needs.

• Reduces operating costs, carbon footprint.

• OEM support through Ford and BPN dealers.

• Creating opportunities for partner companies.

• Using American fuel and American technology.

Page 24: Inspection Guidelines for CNG & LPG Vehicle Conversions

Single Source Engineering and Support

Page 25: Inspection Guidelines for CNG & LPG Vehicle Conversions

Building 87 - RCT Headquarters

•Manufacturing•Complex Assembly•Sales & Marketing•Engineering•Warranty & Field Service

Page 26: Inspection Guidelines for CNG & LPG Vehicle Conversions

State of the Art Facility

Page 27: Inspection Guidelines for CNG & LPG Vehicle Conversions

Building 79 – Vehicle Assembly

Page 28: Inspection Guidelines for CNG & LPG Vehicle Conversions

ORDER PROCESS:Minimizing Time from Order to Delivery

Page 29: Inspection Guidelines for CNG & LPG Vehicle Conversions

Liquid Propane Autogas

Blue Bird VisionMicro Bird G5

Ford F-650Ford F-450/550Ford E-150/250/350/450 Ford F-250/350Ford E-450

Ford F-59 Strip Chassis

Ford E-450 Strip Chassis

Page 30: Inspection Guidelines for CNG & LPG Vehicle Conversions

Propane Powered Vision

Page 31: Inspection Guidelines for CNG & LPG Vehicle Conversions

Blue Bird Bus Dealer

Page 32: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years

2015

Engine Size

6.8L V10 (3V)

Applications

All cab configurations.

All wheelbase configurations.

6-speed automatic transmission.

Fuel Tank Capacity

Mid-Ship: 67 gallons (usable)

Extended: 93 gallons (usable)

Technical Specifications

EPA and CARB approved.

GVWR: 33,000 lbs.

Up to 77 passengers

Order Availability

Blue Bird dealers

Product Overview

Blue Bird Vision(Type C)

Page 33: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years 2015

Engine Size 6.8L V10 (2V)

Applications All cab configurations.

158” / 176” wheelbase configurations.

5-speed automatic transmission.

Fuel Tank Capacity Aft-Axle: 41 gallons (usable)

Technical Specifications EPA and CARB approved.

GVWR: 14,500 lbs.

Up to 30 passengers

Order Availability Blue Bird dealers

Product Overview

Micro Bird G5(Type A)

Page 34: Inspection Guidelines for CNG & LPG Vehicle Conversions

E-250/350/450 E-450 CutawayF-250/350/450/550/650

F-53 / F-59 Strip Chassis E-450 Strip Chassis

Page 35: Inspection Guidelines for CNG & LPG Vehicle Conversions

Order to Delivery ProcessOrder the Vehicle• Check applicable body codes.• Check applicable wheelbase.• Order gaseous fuels prep engine

package.• Enter ship-thru code.• Dealer places order through Ford

Order the Fuel System•Determine tank configuration.

•Dealer places order through ROUSH CleanTech.

Ford Build Process•Ford builds vehicle.•Ford delivers vehicle to ship-thru location.

Ship-Thru Build Process•Complete standard upfit.•Complete propane autogas upfit.

•Vehicle re-enters Ford shipping.

Vehicle Delivery•Vehicle is delivered to destination for final customer delivery.

Page 36: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years

2009 - 2014

Engine Size

5.4L V8 (2V)

Applications

Extended or Regular

Cargo Van, Club Wagon.

All rear-axle configurations.

4-speed automatic transmission.

Fuel Tank Capacity

Mid-Ship: 25 gallons (usable)

In-Cab: 46 gallons (usable)

Technical Specifications

EPA and CARB approved.

GVWR: < 10,000 lbs.

Requires “91G” gaseous fuels prep. package.

Order Availability

Ford Ship Through.

Conversion Kits.

Product Overview

Ford E-250 / E-350

Page 37: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years 2009 - 2014

Engine Size 6.8L V10 (2V)

Applications 158” / 176” / 186” / 190” / 208” wheelbase.

Stretched chassis.

5-speed automatic transmission.

Fuel Tank Capacity Aft-axle: 41 gallons (usable)

Technical Specifications EPA and CARB approved.

GVWR: < 14,500 lbs.

Requires “91G” gaseous fuels prep. package.

Order Availability Ford Ship Through.

Conversion Kits.

Product Overview

s

Ford E-450 Cutaway

Page 38: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years

2012 - 2014

Engine Size

6.2L V8 (3V)

Applications

4x2 or 4x4.

All bed configurations.

All body configurations (including chassis cab).

Fuel Tank Capacity

Under-bed*: 21 gallons (usable)

In-Bed: 38 gallons (usable)

In-Bed Extended Range: 46 gallons (usable)

Technical Specifications

EPA and CARB approved.

GVWR: < 13,300 lbs.

Requires “98F” gaseous fuels prep. package.

Order Availability

Ford Ship Through.

Conversion Kits.

Product Overview

Ford F-250 / F-350

Page 39: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years

2012- 2014

Engine Size

6.8L V10 (3V)

Applications

All cab configurations.

All wheelbase configurations.

5-speed automatic transmission.

Fuel Tank Capacity

Aft-Cab*: 52 gallons (usable)

Shuttle: 65 gallons (usable)

Technical Specifications

EPA and CARB approved.

GVWR: < 16,500 – 19,500 lbs.

Requires “98G” gaseous fuels prep. package.

Order Availability

Shuttle: Q1, 2013 (distributed through GAS only).

Product Overview

Ford F-450 / F-550

Page 40: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years

2012- 2014

Engine Size

6.8L V10 (3V)

Applications

All cab configurations.

All wheelbase configurations.

6-speed automatic transmission.

Fuel Tank Capacity

Skirted: 45 gallons (usable)

Non-Skirted: 83 gallons (usable)

Technical Specifications

EPA and CARB approved.

GVWR: < 30,000 lbs.

Requires “98G” gaseous fuels prep. package.

Order Availability

Available Now

Product Overview

Ford F-650

Page 41: Inspection Guidelines for CNG & LPG Vehicle Conversions

Model Years 2013 - 2014

Engine Size 6.8L V10 (3V)

Applications All wheelbase configurations.

All rear-axle configurations.

5-speed automatic transmission.

Fuel Tank Capacity Aft-axle: 65 gallons (usable)

Technical Specifications EPA and CARB approved.

GVWR F-53: < 26,000 lbs.

GVWR F-59: < 22,000 lbs.

Requires “98G” gaseous fuels prep. package.

Order Availability Available from Green Alternative Systems.

Product Overview

Ford F-53 / F-59Strip Chassis

Page 42: Inspection Guidelines for CNG & LPG Vehicle Conversions

Coming Soon

Ford Transit

Page 43: Inspection Guidelines for CNG & LPG Vehicle Conversions

INSTALLATION PROCESS:Minimizing Time from Order to Delivery

Page 44: Inspection Guidelines for CNG & LPG Vehicle Conversions

Fuel RailROUSH CleanTech’s signatureblue anodized aluminum fuelrail is designed to operate under varying temperaturesof liquid propane

Fuel FillIndustry-standard valve designed toallow for safe passage of liquid pro-pane into the vehicle. Includes a check valve to prevent fuel leaks.

Fuel TankThe liquid propane autogas fuel tankmeets all ASME certification standards,is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA.

Fuel LinesMade of high-durability stainlesssteel to handle varying temperaturesand pressures. They are designed to route through the factory line locations.

Fuel InjectorsSpecial fuel injectors are usedto inject liquid propane into thecylinders for ignition.

FRPCMThe Fuel Rail Pressure ControlModule ensures consistent vehicleperformance and power on-demand.

Page 45: Inspection Guidelines for CNG & LPG Vehicle Conversions

67.5 or 93 gallon capacity tank.

Carbon steel.

Twice the required thickness for ASME Certification

312 PSI working pressure.

Fuel System

Page 46: Inspection Guidelines for CNG & LPG Vehicle Conversions

Fuel System

16 Mounting PointsLocated Inside Frame

Rails

Page 47: Inspection Guidelines for CNG & LPG Vehicle Conversions

E-250/350/450 E-450 CutawayF-250/350/450/550/650

F-53 / F-59 Strip Chassis E-450 Strip Chassis

Page 48: Inspection Guidelines for CNG & LPG Vehicle Conversions

Installation Partners

Located Throughout the U.S.

Trained by ROUSH CleanTech

FORD QVM Certified

Installation maintains factory Ford warranty

Page 49: Inspection Guidelines for CNG & LPG Vehicle Conversions

ROUSH CleanTech LPG System Overview

The ROUSH CleanTech LPG system is a dedicated liquid propane injected system and completely replaces the OEM fuel system.

The conversion process involves removing the OEM fuel tank assembly, the evaporative emissions assembly, the fuel line assembly and the fuel rail assembly.

The vehicle then has the ROUSH CleanTech LPG system installed on it. An overview of the system hardware is shown.

Page 50: Inspection Guidelines for CNG & LPG Vehicle Conversions

Fuel Rail Assembly– Fuel Rails– Fuel Injectors– Injection Press. / Temp.

Sensor

Fuel Line Assembly– Fuel Lines– Flow Control Solenoid

Fuel Tank Assembly– Fuel Tank– Fuel Pump– Fuel Level Sensor

System Installation Overview

Powertrain Control System– PCM Calibration– Wiring Harness

Page 51: Inspection Guidelines for CNG & LPG Vehicle Conversions

Ford E-450

Fuel RailROUSH CleanTech’s signatureblue anodized aluminum fuelrail is designed to operate under varying temperaturesof liquid propane

Fuel FillIndustry-standard valve designed toallow for safe passage of liquid pro-pane into the vehicle. Includes a check valve to prevent fuel leaks.

Fuel TankThe liquid propane autogas fuel tankmeets all ASME certification standards,is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA.

Fuel LinesMade of high-durability stainlesssteel to handle varying temperaturesand pressures. They are designed to route through the factory line locations.

Fuel InjectorsSpecial fuel injectors are usedto inject liquid propane into thecylinders for ignition.

FRPCMThe Fuel Rail Pressure ControlModule ensures consistent vehicleperformance and power on-demand.

Page 52: Inspection Guidelines for CNG & LPG Vehicle Conversions

Ford E-150 / E-250 / E-350

Fuel RailROUSH CleanTech’s signatureblue anodized aluminum fuelrail is designed to operate under varying temperaturesof liquid propane

Fuel FillIndustry-standard valve designed toallow for safe passage of liquid pro-pane into the vehicle. Includes a check valve to prevent fuel leaks.

Fuel TankThe liquid propane autogas fuel tankmeets all ASME certification standards,is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA.

Fuel LinesMade of high-durability stainlesssteel to handle varying temperaturesand pressures. They are designed to route through the factory line locations.

Fuel InjectorsSpecial fuel injectors are usedto inject liquid propane into thecylinders for ignition.

FRPCMThe Fuel Rail Pressure ControlModule ensures consistent vehicleperformance and power on-demand.

Page 53: Inspection Guidelines for CNG & LPG Vehicle Conversions

Ford E-150 / E-250 / E-350

Fuel RailROUSH CleanTech’s signatureblue anodized aluminum fuelrail is designed to operate under varying temperaturesof liquid propane

Fuel FillIndustry-standard valve designed toallow for safe passage of liquid pro-pane into the vehicle. Includes a check valve to prevent fuel leaks.

Fuel TankThe liquid propane autogas fuel tankmeets all ASME certification standards,is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA.

Fuel LinesMade of high-durability stainlesssteel to handle varying temperaturesand pressures. They are designed to route through the factory line locations.

Fuel InjectorsSpecial fuel injectors are usedto inject liquid propane into thecylinders for ignition.

FRPCMThe Fuel Rail Pressure ControlModule ensures consistent vehicleperformance and power on-demand.

Page 54: Inspection Guidelines for CNG & LPG Vehicle Conversions

ROUSH CleanTech LPG System Overview

Page 55: Inspection Guidelines for CNG & LPG Vehicle Conversions

Underfloor Tank

Page 56: Inspection Guidelines for CNG & LPG Vehicle Conversions

Ford F-250 / F-350

Fuel RailROUSH CleanTech’s signatureblue anodized aluminum fuelrail is designed to operate under varying temperaturesof liquid propane

Fuel FillIndustry-standard valve designed toallow for safe passage of liquid pro-pane into the vehicle. Includes a check valve to prevent fuel leaks.

Fuel TankThe liquid propane autogas fuel tankmeets all ASME certification standards,is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA.

Fuel LinesMade of high-durability stainlesssteel to handle varying temperaturesand pressures. They are designed to route through the factory line locations.

Fuel InjectorsSpecial fuel injectors are usedto inject liquid propane into thecylinders for ignition.

FRPCMThe Fuel Rail Pressure ControlModule ensures consistent vehicleperformance and power on-demand.

Page 57: Inspection Guidelines for CNG & LPG Vehicle Conversions

Ford F-250 / F-350

Fuel RailROUSH CleanTech’s signatureblue anodized aluminum fuelrail is designed to operate under varying temperaturesof liquid propane

Fuel FillIndustry-standard valve designed toallow for safe passage of liquid pro-pane into the vehicle. Includes a check valve to prevent fuel leaks.

Fuel TankThe liquid propane autogas fuel tankmeets all ASME certification standards,is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA.

Fuel LinesMade of high-durability stainlesssteel to handle varying temperaturesand pressures. They are designed to route through the factory line locations.

Fuel InjectorsSpecial fuel injectors are usedto inject liquid propane into thecylinders for ignition.

FRPCMThe Fuel Rail Pressure ControlModule ensures consistent vehicleperformance and power on-demand.

Page 58: Inspection Guidelines for CNG & LPG Vehicle Conversions

F-450 / F-550 Aft-Cab

Aft-Cab Tank: 52 usable

gallon capacity

Page 59: Inspection Guidelines for CNG & LPG Vehicle Conversions

F-650 Saddle Tanks

Skirted Body Tanks: 45 total usable gallon capacity

Non-Skirted Body Tanks: 83 total usable gallon capacity

Page 60: Inspection Guidelines for CNG & LPG Vehicle Conversions

The tank mounting plates are structurally mounted to the floor or frame using a total of (10) M12 bolts, with backing plates in all locations that do not already have a Ford structural anchor.

The tank is then isolation-mounted to these plates, providing structural and noise isolation between the tank and the floor so that any body flex does not result in stresses on the tank.

This system is designed to ROUSH CleanTech’s internal mounting standards (tank will not become dislodged in 20g front crash, 8g side / rear) which is double the NFPA standard.

This ensures that the tank itself does not become dislodged in an accident.

Propane Autogas Tank Safety Features

Page 61: Inspection Guidelines for CNG & LPG Vehicle Conversions

Phillip MaileyBusiness Development Manager – North Central Region

[email protected]

Together We Practice Environmental Responsibility

Together We Are Innovative

Together We Succeed

Page 62: Inspection Guidelines for CNG & LPG Vehicle Conversions

Turbocharged Natural Gas™ Dual Fuel System• Accelerating Natural Gas Adoption in Legacy HD Fleets

• South Shore Clean CitiesWebinar

• January 28th, 2014

Page 63: Inspection Guidelines for CNG & LPG Vehicle Conversions

Publicly Traded Company (OTCQB – APGI)

22 employees/Forecasted revenue in fiscal 2014: $14M

Facilities

Operations & Worldwide Distribution Center

Calibration & Emissions Tech Center

University of West Virginia Diesel Test Cell

Algona, IA

Detroit, MI

Morgantown, WV

2

Leader in the Dual Fuel Natural Gas Conversions

#1 in EPA engine approvals and units sold

Page 64: Inspection Guidelines for CNG & LPG Vehicle Conversions

New EPA Clean Alternative Fuel EngineConversion Categories

0

435000

870000

1305000

0 2 4 6 8 10Engine Model Year Past Current

12 14 16

Engi

ne M

ileag

e (m

i)

Outside Useful LifeApproval

Inside Useful Life Approval

Full OEMCert

3

EPA-

APPROVE

D

DES

I GNED I N

D ET R OI T

Page 65: Inspection Guidelines for CNG & LPG Vehicle Conversions

APG Engine Family Status for EPA Approvals

OUL: Caterpillar C11, C13, C15

2006 – 2004

C-16

C-10, C-12, C-15

ISX, ISM, ISL, ISC

N14, M11, L10,

C8.3 DD15, DD13

DD13 12.8L

Series 60 14.0L

Series 60 12.7L, 11.1

MBE 4000 12.8L

OM457LA, OM460LA

D11, D12, D13, D16

VE D12

MP7, MP8,

MP10 E7

EM7

2002 – 1997

2003 – 1996

2009 – 1998

2001 – 1991

2009 – 2008

2009

2009 – 1999

2006 – 1987

2009 – 2001

2003 – 2000

2009 – 2004

2002 – 1996

2006 – 2002

2006 – 1996

2002 – 1996

IUL – SCR(MY 2010 – 2012)

Cummins

Detroit Diesel Volvo/Mack (Jan ‘14)

Detroit Diesel (Mar

‘14) Cummins (May

‘14)

Daimler

Volvo

Mack

4

EPA-

APPROV

EDD

ESI G

NED I N

D ET R OI T

Note: Some engines may not have been produced in each year shown above and some horsepower ratings may not be included. Contact APG or an authorized distributor for more details

Page 66: Inspection Guidelines for CNG & LPG Vehicle Conversions

Turbocharged Natural Gas™ Technology V5000 Dual Fuel Upgrade System

66

Page 67: Inspection Guidelines for CNG & LPG Vehicle Conversions

V5000 Engine Kit Installed

3% by volume of NaturalGas in the turbo chamber.LEL(Lower Explosion Limit requires 5-15% by volume)

ECM wire harness

Low pressure regulator

Throttle body to control NG substitution %

Remote Display Unit

67

Page 69: Inspection Guidelines for CNG & LPG Vehicle Conversions

CNG Tank Installation

90” CNG tank = 46 DGE

60” CNG tank = 30 DGE

8

Page 70: Inspection Guidelines for CNG & LPG Vehicle Conversions

90” LNG tank = 78 DGE

9

50” LNG tank = 37 DGE

LNG Tank Installation

Page 71: Inspection Guidelines for CNG & LPG Vehicle Conversions

10

90” CNG tank = 46.5 DGE

90” LNG tank = 78 DGE

LNG / CNG Tank Capacity Comparison

90”

Page 72: Inspection Guidelines for CNG & LPG Vehicle Conversions

Tank Safety

WheelTime and APG only utilize tank manufacturers that comply to NFPA52 tank safety standards.

• Drop Test

• Gunfire

• Bonfire

• Cycle Test

• Burst

• Boss torque

• Impact/Chemical exposure

• Flaw tolerance

72

Page 73: Inspection Guidelines for CNG & LPG Vehicle Conversions

Why purchase an APG V5000 system?

A A A

Lower your overall fuel cost

B B

Today 100% Diesel

$4ppg

Dedicated 100% Nat

Gas$2ppg

APG System

50/50 Blend$3ppg B

73

Page 74: Inspection Guidelines for CNG & LPG Vehicle Conversions

CNG Customer Economics – Dual FuelClass 8 Tractor/TrailerEstimated Miles Driven/Year

120,000 miles

Diesel Only

Estimated MPG 5.5

Annual Diesel Consumption 21,800 gallons

Annual Cost @ $4.00/gallon $87,000/year

Dual Fuel @ 50%

Annual Diesel Consumption 10,900 gallons

Annual Cost @ $4.00/gallon $44,000/year

Equivalent CNG Consumption 10,900 gallons

Annual Cost @ $2.00/DGE $22,000/year

Total Annual Dual Fuel Costs

$66,000/year

Estimated Annual Savings

$21,000 (25%)

Return on Investment(ROI)

17 months ($32k system)*Depends on mileage range and tank

capacity

$80,000.00

$70,000.00

$60,000.00

$50,000.00

$40,000.00

$30,000.00

$20,000.00

$10,000.00

$0.00

$90,000.00

Annual Fuel Cost (100% diesel)

Annual Fuel Cost (Dual Fuel)

$87,272.73

$65,454.55

Do

llar

s p

er Y

ear

Estimated Annual Fuel Savings

Insert CNG or LNG price per gallonThe price differential between NG and diesel is the savings

13

Page 75: Inspection Guidelines for CNG & LPG Vehicle Conversions

Introducing the APG Dual Fuel Glider™

Best Natural Gas Trucks on the Road!

• Lowest Purchase Price for a New Natural Gas Truck

• Net Dual Fuel Savings: $0.12 - $0.20 / mile

• Additional Maintenance & DEF Savings

• Attractive Financing Plans Available

EPA-

APPROV

EDD

ESI G

NED I N

D ET R OI T

75

Page 76: Inspection Guidelines for CNG & LPG Vehicle Conversions

Glider Video

http://www.ccjdigital.com/video-log-fueling-driving-natural-gas-glider-kit 76

Page 77: Inspection Guidelines for CNG & LPG Vehicle Conversions

181+ Locations

3,500 Technicians

2,800 Service bays

1,500 Service Vehicles

Distribution Network (Installation/Service)

,. 77

Page 79: Inspection Guidelines for CNG & LPG Vehicle Conversions

Key Factors to Natural Gas SuccessThe Dual Fuel Industry is a Game-Changer

Abundant Natural Gas # of Fill Stations

LNG

CNG

Competitive Tank Storage

- Compressed Natural Gas (CNG)

Viable Dual Fuel Users

- Economic

Diesel

LNG DEF

- Liquefied Natural Gas (LNG)

- Environmental

79

Page 80: Inspection Guidelines for CNG & LPG Vehicle Conversions

APG EPA Approvals and Target Fleets

Intermediate Useful Life (IUL)

Existing Used Trucks @

2 years old

Approval Type

Targeted Fleet Attributes

Outside Useful Life (OUL)

Existing Used Trucks @

10 years old or 435,000 mi

Glider Kits

Use a re-man OUL engine

Install in new tractor

Approval Status

Smaller Fleets

Owner / Operator

Longer Trade Cycles (>7 yrs)

Buys Used Trucks

Re-man their own engines

Small Fleets

Large Fleets

Owner / Operator

Small Fleets

Large Fleets

Owner / Operator

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Key Takeaways of APG system

81

1. Fast ROI - SAVES YOUR FLEET MONEY!

Saves $.10 to $.20 per mile

12-24 month payback

System can be transferred to other trucks

Convert 6 trucks with APG system for the same price as 1 new dedicated NG truck

2. Your engine is still a diesel engine

Natural Gas introduced into air intake (pre-turbo)…non-

invasive No loss in power, torque nor fuel economy

No range anxiety - runs on 100% diesel if natural gas tank runs

out No change to existing maintenance schedule

3. EPA approved…over $8M invested to obtain approvals

448 OUL approvals

IUL approvals coming in 2014

4. Best and most reliable dealer service & install network

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Barnes Green Energy was created to provide alternatives to conventional fuels which are not only

cost effective but provide a “Green Solution” to vehicle fleet owners and managers

Page 85: Inspection Guidelines for CNG & LPG Vehicle Conversions

• The US Dept of Energy now forecasts a growing supply of natural gas that extends into the next century. New technologies that have evolved allow natural gas production to ramp up to a level not foreseen a decade ago.

• To take advantage of this natural gas fuel abundance, and the resulting price advantage at the pump, Barnes Green Energy (BGE) was organized in April 2013 to develop infrastructure and provide fuel system conversions for compressed natural gas as a vehicle fuel.

• BGE not only provides EPA Certified Natural Gas (CNG) fuel system conversions but offers a CNG fueling facility at our Nesbitt Road location in Madison in partnership with U.S. Oil/Gain Clean Fuel, which will come on line in the Spring of 2014.

Page 86: Inspection Guidelines for CNG & LPG Vehicle Conversions

Fuel System Conversions

•BGE along with its business partner Barnes Power Equipment (BPE), have converted thirty vehicles to CNG fueling since starting in the fall of 2012.

Of these, twenty conversions are for the Barnes Inc. fleet. The remaining ten are for other fleet owners such as United Beverage, Great Lakes Conservation Corp., UW Provision, Center Point Energies, and others.

•BPE employs Certified Technicians for CNG conversions for GM, Chrysler (NatGasCar ) and Ford ( Altech Eco ) using conversion systems provided by the major CNG fueling system providers noted above.

Page 87: Inspection Guidelines for CNG & LPG Vehicle Conversions

Fuel System Conversions

Timeline for conversions

Typical conversions will take 2 – 3 days for completion once the pieces / parts have arrived at our shop in Madison.

Conversion Costs

Costs for conversions vary depending on vehicle make, year, engine size, original fuel type ( gasoline or diesel ), and number and size of tanks installed. The number and size of tanks are a major cost component in conversions, and are driven by desired range for the vehicle, among other considerations.

Page 88: Inspection Guidelines for CNG & LPG Vehicle Conversions

Fuel System Conversions

There are three types of aftermarket conversions currently available.

The most common conversion is “U.S. EPA Certified”, and covers the current model year as well as the previous two model year’s vehicles.

The second type of conversion is commonly called “Intermediate - Approval by U.S. EPA”, and the third type is “Outside Useful Life - Approval by U.S. EPA”

The link below will take you to a complete listing of vehicles and engines for which conversions are available:

http://www.ngvamerica.org/pdfs/Available_Vehicles_and_Engines.pdf 

Page 89: Inspection Guidelines for CNG & LPG Vehicle Conversions

Fuel System Conversions

CNG Cylinders ( tanks )

Presently there are four types of tanks available, designated by a number.

Type 1 tanks are all metal, steel or aluminum; Type 2 are a metal liner hoop wrapped with a composite material, usually fiberglass or carbon fiber. Type 3 tanks also use a metal liner but the liner is completely covered by the composite material. Type 4 tanks are composed of a gas tight plastic inner cylinder fully enclosed by a composite covering.

Pricing for these tanks escalates rapidly as you move from Type 1 to Type 4 tanks.

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CNG Tank Installation Example

Page 91: Inspection Guidelines for CNG & LPG Vehicle Conversions

Useful Links:

Barnes Green Energyhttp://barnesgreenenergy.com/Wisconsin Clean Citieshttp://www.wicleancities.org/Natural Gas Vehicle Institutehttp://www.ngvi.com/Alternative Fuels Data Center – Natural Gas Vehicleshttp://www.afdc.energy.gov/vehicles/natural_gas.htmlAlternative Fuels Data Center - Toolshttp://www.afdc.energy.gov/toolsAlternative Fuels Data Center - Calculatorhttp://www.afdc.energy.gov/calc/Alternative Fuels Station Locator – U.S. and Wisconsinhttp://www.afdc.energy.gov/locator/stations/

Page 92: Inspection Guidelines for CNG & LPG Vehicle Conversions

CONTACT INFORMATION

NAME: Jim Montgomery

Email: [email protected]

www.barnesgreenenergy.com

Phone: 608-395-8149 Cell, or 608-845-3230 Office