isx g and lng system owner's manual -...
TRANSCRIPT
GX and LNG System Operator’s
Manual
EPA 07 and ADR80/02
Models
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Emergency Situations• Fireon-boardthevehicle
• Uncontrolledseverenaturalgasleak
• AnyothercircumstancerequiringassistancefromEmergencyPersonnel
Emergency Response Procedure
Gas Leak Classification and ResponseSevere:
• UncontrolledspillorsprayofLNG
• Aleakwhichresultsinalargevaporcloud
• Anyleakwherethevehicleislocatedinaplacewheregasmayaccumulate
• Anyleakwhereasourceofignitionisincloseproximitytothevehicle
Response:followEmergencyResponseProcedure
Significant:
• On-boardgasdetectorisinalert(redindicatorlight)
• Noother“Severe”conditions
Response:seeSection 3.3—Gas Detection Monitor: Table 3—Gas detection interpretation
Trace:
• On-boardgasdetectorisintracealarm(yellowindicatorlight)
• Noother“Severe”or“Significant”conditions
Response:seeSection 3.3—Gas Detection Monitor: Table 3—Gas detection interpretation
Driver Safety – Quick Reference Page
Find a safe place to pull over
Turn off engine
Turn off Emergency Shut-off Valve (if equipped) and Accumulator Isolation Valve
IF SAFE TO DO SO
Call Emergency Responders Inform them that LNG and CNG are on board
Clear and secure the largest practical perimeter
Inform shop / dispatch
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Westport™ GX and LNG System Operator’s Manual EPA 07 and ADR80/02 Models
©2008,2009WestportPowerInc.
Allrightsreserved.Nopartofthisdocumentmaybereproduced,storedinaretrievalsystem,ortransmittedinanyform,byanymeans,withoutthepriorwrittenpermissionofWestportPowerInc.
ThisdocumentiswrittenandpublishedbyWestportPowerInc.inVancouver,BritishColumbia,CanadaforWestportPowerInc.anditsaffiliates.Everyprecautionhasbeentakentoensureitsaccuracy.Ifyoudofindanerror,pleasecontactus.WestportPowerInc.anditsaffiliatesassumenoresponsibilityforerrorsinthisdocument,omissions,ortheirconsequences.Theinformationissubjecttochangewithoutnotice.
Ifyouhaveanyquestionsabouttheinformationinthisguide,orifyouneedserviceassistance,pleasecontacttheWestportHeavy-DutyServiceTeam.
North America:
Toll-free: 1-888-WPT-HPDI 1-888-978-4734E-mail: [email protected]: http://www.westport-hd.com http://service.westport.com
ForalistingoflocalservicecontactsrefertoAppendix C—Contact Informationofthismanual.
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Table of ContentsDriver Safety – Quick Reference Page iiList of Figures and Tables viAbout This Guide viiDefinitions and Acronyms viiiGeneral Safety Instructions ix1. Description of the Westport LNG System 1
1.1 What the Westport LNG System Is 11.2 What the Westport LNG System Does 11.3 How the Westport LNG System Works 11.4 Location of Westport LNG System Components 1
1.4.1 Inside the Cab 11.4.2 Inside the Engine Bay 31.4.3 Outside the Engine Bay 5
2. Pre-Trip Inspection 112.1 Check Inside the Cab 112.2 Check Inside the Engine Compartment 122.3 Check Outside the Engine Compartment 13
3. Starting and Driving 153.1 Starting the Engine 153.2 Westport LNG System Monitor 16
3.2.1 Top Westport LNG System Display Window 163.2.2 Bottom Westport LNG System Display Window 17
3.3 Gas Detection Monitor 173.4 Turning the Truck Off 193.5 Post-Trip Inspection 193.6 Exhaust Aftertreatment Considerations 193.7 Parking—General and for Maintenance 20
4. Westport LNG System Safety Precautions 214.1 Fuels 21
4.1.1 Liquefied Natural Gas 214.1.2 Natural Gas Vapor and CNG 214.1.3 Diesel 22
4.2 High Pressure 234.3 Pressure Safety Devices 23
4.3.1 Automatic Relief Valves 234.3.2 Manual Valves 25
4.4 Gas Leaks Classification and Response 264.5 Emergency Response 27
5. Safe LNG Truck Fueling 285.1 LNG Fueling Safety Equipment 28
5.1.1 Recommended Personal Protective Equipment 285.1.2 Truck Equipment 28
5.2 LNG Fueling Basics 295.3 Incident Reaction 30
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5.4 Pre-Fueling 315.5 LNG Fueling 315.6 Venting 33
5.6.1 Venting to Station 335.6.2 Venting to Atmosphere 34
5.7 Minimizing Venting and Fuel Loss 36
6. Westport LNG System Maintenance and Care 376.1 Maintenance Schedules 37
6.1.1 Natural Gas Code Required Maintenance 406.1.2 Oil Drain Intervals 40
6.2 Recommended Fluids and Capacities 416.2.1 LNG Composition Specifications 416.2.2 LNG Cleanliness Specifications 416.2.3 Lubricating Oil Specifications 416.2.4 Coolant Specifications 426.2.5 LNG Pump / Steering Fluid Specifications 426.2.6 Diesel Fuel Specification 426.2.7 Biodiesel Fuel Use in the LNG System 436.2.8 Usable LNG Tank Sizes 43
6.3 Fuel Weathering 446.4 Running on Diesel (ROD) Operation 446.5 Minimizing Tank Contamination 44
7. Diagnostics and Troubleshooting 457.1 Frozen Valves 457.2 Leak at Tank Fuel Receptacle 467.3 Excessive “Please Wait…” Message Time 46
7.4 Crank, But No Start Condition 467.5 Difficulty Fueling with LNG 477.6 Jump Starting your LNG Truck 477.7 Sweaty LNG Tank / Low Fuel Efficiency 47
8. LNG Properties and Handling 498.1 Physical Properties 498.2 Safety Hazards 498.3 First Aid 508.4 Sample LNG MSDS 50
Appendix A. Daily Log Sheet 54Appendix B. Towing and Recovery 58Appendix C. Contact Information 59
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List of Figures and TablesFigure 1 Westport LNG System Monitor 2Figure 2 Gas detection monitor 2Figure 3 Engine bay 4Figure 4 LNG tank and plumbing 7Figure 5 Westport LNG System Controllers, high-pressure
accumulator, and associated plumbing 8Figure 6 Vent stacks, filter, and drain port 9Figure 7 Remote fill panel 10Figure 8 Secondary relief valve 13Figure 9 Westport LNG System Monitor 15Figure 10 Westport LNG System Monitor 16Figure 11 Gas detection monitor 17Figure 12 Gas detection monitor – [PUSH TO TEST] button 18Figure 13 LNG tank shroud automatic pressure relief valves 24Figure 14 High-pressure accumulator plumbing 24Figure 15 LNG tank shroud manual pressure relief valves 25Figure 16 LNG tank ground clamp attachment 32Figure 17 Remote fill panel attachments 32Figure 18 Tank shroud labels 35
Table 1 Westport LNG System Monitor messages 17Table 2 Gas detection zone assignment 17Table 3 Gas detection interpretation 18Table 4 Automatic relief valves and devices 23Table 5 Manual valves 25Table 6 Oil drain intervals 40Table 7 LNG tank volumes 43
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About This GuideThis guide covers the Westport LNG System.
ThisguideisforoperatorsoftrucksusingtheWestportliquefiednaturalgas(LNG)Systemwithhigh-pressuredirectinjection(HPDI)technology.SupplementalWestportLNGSystemOperatorTrainingisalsoavailable.FormoreinformationontrainingortheWestportLNGSystem,pleaseusethecontactinformationlistedinAppendix C—Contact Information.
ThisguidecontainsthebasicinformationyouneedtoknowabouttheWestportLNGSystemonyourtruck.RefertotheOEMOperator’sManualprovidedwithyourtruckforotheroperationandmaintenanceinformation.
Thisguideprovides:
• WestportLNGSystemoverview
• WestportLNGSystemspecificoperatingprocedures and guidelines
• WestportLNGSystemsafetyprecautions
• WestportLNGSystemmaintenanceandcare
• Fuelingprotocolandsafety
AfteryoubecomefamiliarwiththeWestportLNGSystemanditscomponents,youcanusetherestofthisguideasareferenceandsourceofinformationontheWestportLNGSystem.
Westportwelcomesyourcomments,suggestions,andquestions.YoucancontactyourlocalWestportServicerepresentativelistedinAppendix C—Contact Informationofthisguide.
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Definitions and AcronymsWARNING!
Serious personal injury or extensive property damage can result if the warning instructions are not followed.
API AmericanPetroleumInstitute
°C Celsius
CARB CaliforniaAirResourceBoard
CGA CompressedGasAssociation
CNG compressednaturalgas
DPF dieselparticulatefilter
ECU electroniccontrolunit
ESD emergencyshut-down
EPA EnvironmentalProtectionAgency
°F Fahrenheit
FCM FuelConditioningModule
GVW grossvehicleweight
hp horsepower
HPDI high-pressuredirectinjection
km/h kilometersperhour
kPa kilopascal
L liters
LEL lowerexplosivelimit
LNG liquefiednaturalgas
MPa megapascal
mph milesperhour
MSDS MaterialSafetyDataSheet
NFPA NationalFireProtectionAgency
NG naturalgas
OEM originalequipmentmanufacturer
PPE personalprotectiveequipment
PRV pressurereliefvalve
psi poundspersquareinch
ROD runningondiesel
rpm revolutionsperminute
CAUTION! Minor personal injury can result or a part, an
assembly, or the engine can be damaged if the caution instructions are not followed.
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General Safety InstructionsWARNING!
Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death
ReadandunderstandallofthesafetyprecautionsandwarningsbeforeuseoftheWestportLNGSystemtruck.Thislistcontainsthegeneralsafetyprecautionsthatmustbefollowedtoprovidepersonalsafety.
Naturalgasislighterthanairandcanaccumulateinenclosedspaces,suchasunderthehoodorunderawnings.Ifthereisanignitionsource,anexplosioncouldresult.
PARKINGOUTSIDEISMANDATORYduetonormalventingofnaturalgas.
Naturalgasiscolorlessandodorless.Somenaturalgassuppliersaddanodoranttonaturalgas.However,liquefyingnaturalgasdestroysthisodorant.
WestportLNGSystemtrucksareequippedwithagasdetectionmonitor.Youmustchecktheoperationofthegasdetectionmonitorandlistenforsoundsofaleak.Ifyoudetectsignsofaleak,seeredoryellowlights,hearagasalarm,orcannotseethegreenpowerlightonthedetector,doNOTenteroroperatethetruck.Notifytheshopfromoutsidethetruck.
Donotstayinanaturalgasvaporcloud.Naturalgasdisplacesoxygenandwillcauseasphyxiation.
TheWestportLNGSystemcontainshighpressuregas,liquid,andcryogenicfluid—evenwhenthetruckisturnedoff.NounauthorizedoruntrainedpersonshouldEVERattemptmaintenanceorrepairsonaWestportLNGSystemtruck.Donotturnvalvesyouareunfamiliarwith.Highpressureblastorcryogenicburninjuriescouldoccur.
WestportLNGSystemrepairsmustbecompletedonlyatCertifiedWestportLNGSystemshops.
Onlyoperate“ServiceOnly”valvesifyouareaqualifiedWestportLNGSystemstechnician.
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Releaseofhighpressuregasorfluidcanbreakorpropelcomponentswithexplosiveforce.
LNGisacryogenic(extremelycold)fluid,whichmustbestoredatcryogenictemperatures.Avoidcontactwithliquidandplumbing.Freezingburnsandlacerationscouldoccur.
Wearappropriatepersonalprotectiveequipment(PPE)whenfuelingorworkingaroundtheLNGtankorplumbing.
Tankpressurecanrise275kPa(40psi)perdaywhenthetruckisparked.
Iftankpressurereadszero,notifytheshopasthismayindicatealeak.
Fuelingrecommendationsinthismanualareforguidelinepurposesonly.YoumustreceivetrainingtoyourspecificLNGfuelingstation.
General Safety Instructions (continued)Naturalgasvaporisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.WestportrecommendsnotsmokingwhileoperatingaWestportLNGSystemtruck
DamagetotheWestportLNGSystemcanoccurifthecoolantmixtureisincorrect.Ensurecoolantmixturecontainsapprovedantifreeze.
Containliquidspillsasbestaspossibletopreventtheliquidorgasfromenteringthesewage/stormdrainsystem.Keeptheresultingvaporcloudawayfrombuildingsorventilationsystems.
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1. Description of the Westport LNG SystemThissectiondescribestheWestportLNGSystemanditscomponents.
1.1 What the Westport LNG System IsTheWestportLNGSystemisafuelinjectionsystemdevelopedbyWestportPowerInc.Itallowsdieselenginestousenaturalgasastheprimaryenginefuel.
1.2 What the Westport LNG System DoesBysubstitutingover95%ofdieselfuelwithcleanburningnaturalgas,atruckusingtheWestportLNGSystemsignificantlyreducesemissionsandmaintainsthesamepowerandperformanceasanequivalentdiesel-onlytruck.
1.3 HowtheWestportLNGSystemWorksLNGisdrawnfromtheLNGtankandispressurizedbythetank-mountedLNGpump.Usingwarmenginecoolant,avaporizer(heatexchanger)warmsthehigh-pressureLNG,changingittohigh-pressurenaturalgasvapor.Thishigh-pressurevaporiscalledcompressednaturalgas(CNG)andprovidesprimaryfueltotheengine.
Simultaneously,dieselisdrawnfromthedieseltanktoanengine-mounted,high-pressuredieselpump.Thehigh-pressuredieselisfedtotheFuelConditioningModule(FCM)thatcontrolsthedieselpressuretotheinjectors.
Insidetheengine,aspecialHPDIinjectordeliversasmallamountofdieselfueland,almostsimultaneously,alargeamountofcompressednaturalgasintothedieselenginecombustionchamber.Thedieselfuelignitesthenaturalgas,whichthenprovidestheengine’spowerstroke.
1.4 Location of Westport LNG System Components
WestportLNGSystemcomponentsarelocatedinthreegenerallocationsonthetruck:
1.4.1 Inside the Cab
TheWestportLNGSystemaddstwospecializedmonitorstothestandarddashboarddisplays:
• Westport LNG System MonitorIndicatestheWestportLNGSystemstatus,includingLNGfuellevelandsystemparameters.Displaysstatusandsystemfaultmessages(seeSection 3.2— Westport LNG System Monitorformoreinformation).
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1.4.1 Inside the Cab (continued)
• Westport LNG System Monitor (continued)
TANK 1
Figure 1—Westport LNG System Monitor
• Gas Detection MonitorMonitorsandindicatesnaturalgasleaksfromthesystemintwokeyzones:inside the cabandinside the engine bay.
Ifgasdetectionmonitorisnotasshown,refertoOEMsupplementaldocumentation.
Cab
Engin
e Bay
GASCONCENTRATION:
SilenceEngaged
RelayEngaged
Pushto
Silence
RelayReset
Pushto
Test
Figure 2—Gas detection monitor
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1.4.2 Inside the Engine Bay
• Fuel Conditioning Module (FCM)Amanifoldthatcontrolspressureandsupplyofnaturalgasanddieseltotheengine.Itcontainsadieselsafetyreliefvalve,aswellasagasventvalveforsystemmaintenance.
• High-Pressure Diesel Pump AnenginemountedpumpwhichisbeltdrivenoffacustomWestportcrankshaftpulley.Thepumpprovideshigh-pressuredieseltotheFCM.
• Low-Pressure Diesel PumpAframe-mounteddieselliftpumpthatincorporatesafirstchancefilterandwaterseparator.
• HPDI Injectors HPDIinjectorsreplacetheoriginaldieselinjectorsanddeliverbothdieselandnaturalgasintothecombustionchamber.
• Hydraulic Reservoir Mountedintheenginebay,thereservoirprovideshydraulicfluidtoruntheLNGpumpaswellasthepower-assistedsteeringsystem.
• Engine Oil FillLocatednearthevalvecover,theengineoilfillreplacesthebaseengineoilfilltoincorporatetheinjectorwireharnesspassthrough.
• High-Pressure Hydraulic PumpAdualvanehydraulicpumpthatprovideshigh-pressurehydraulicfluidtodriveLNGpump(s),andoperatesthebaseenginepowersteeringcircuit.
• Hydraulic Oil CoolerMountedbeneaththeradiatorbetweenthebumpersupportandforwardenginemount,behindthecab,orinthecoolingpack,thisitemcoolsthehydraulicfluid.
• Dosing Pump ThedosingpumpisequippedontrucksfittedwithanintegratedCumminsParticulateFilter.
Wherefitted,thispumpsuppliesfueltothedieselparticulatefilter(DPF)aspartoftheexhaustaftertreatmentsystem.
SeeOEMmanualsanddocumentationformoreinformationregardingtheexhaustaftertreatmentsystem.
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1.4.2 Inside the Engine Bay (continued)
Figure 3—Engine bay (other configurations possible)
Vent stack filter
High-pressure hydraulic pump
Dosing pump
Low-pressure diesel pump
High-pressure diesel pump
Hydraulic reservoir
Engine oil fill
FCM
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1.4.3 Outside the Engine Bay
• LNG Storage Tank(s)OneormorestainlesssteelLNGtanksaremountedontheframerailorbehindthecab.BecausethetankholdsLNG,whichisextremelycold,itisconstructedasadouble-walledvessel.Theinnerandouterwallsareseparatedbyinsulationandavacuumspacetoprovideexcellentprotectionfromtheoutsideenvironment.ThisinsulationkeepstheLNGtemperaturelowforlongerperiodsoftime.Westportofferssingleormultipletankconfigurations.
• LNG Pump TheLNGpumpismountedinsidethetank(seeFigure 4).Thepumpdrawsandpressurizesliquefiednaturalgas,whichisvaporizedwiththeaidofwarmenginecoolantintocompressednaturalgasthatisdeliveredtothehigh-pressureaccumulator(seeFigure 5).
• LNG Tank Valves(see Figure 4)
Automatic Pressure Relief Valves (PRV)LocatedinsidetheLNGtankshroud,thepressurereliefvalvesprotectthesystemfromover-pressure.Intheeventofanover-pressurecondition,thevalvesventtheexcessgasthroughtheventstackintotheatmosphere.TheLNGtankisequippedwithaprimaryandasecondaryreliefvalve:
Primary Relief ValveAvalvedesignedtoopenwhentankpressureexceeds1,600kPa(230psi).Itclosesautomaticallywhentankpressurefallsbelow1,600kPa(230psi).
Secondary Relief Valve Avalvedesignedtoopeniftankpressureexceeds2,200kPa(315psi),iftheprimaryreliefvalvemalfunctions.Itisequippedwithasafetycaptokeepdebrisandmoistureoutofthevalve.However,thiscapwillblowoffwhenthevalveopens,indicatingapossibleprimaryreliefvalvemalfunction.ThepresenceofthiscapmustbecheckedduringthePre-TripInspection(seeSection 2.3—Check Outside the Engine Compartment).
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1.4.3 Outside the Engine Bay (continued)
• LNG Tank Valves(continued,see Figure 4)
Manually Operated ValvesPrimarilylocatedinsidetheLNGtankshroud,includes:
Manual Emergency Shut-Off Valve (if equipped) LocatedbelowtheLNGpump,theprimaryfunctionistoshutoffthegasexitingfromtheLNGpumpandtank.Thisvalve(redhandle)mustbeopenduringnormaloperation.The“TankShut-OffValveClosed”messageisdisplayedontheWestportLNGSystemMonitorwhenthevalveisclosed(seeSection 3.2—Westport LNG System Monitor).Somemodelsareequippedwithanautomaticversionofthisvalve.
Vent-to-Station ValveLocatedinsidethetankshroudontheleft-handside,thisvalvecontrolsthereturnofexcessfuelvaportothestation.Theexcessvaporissafelyreturnedthroughthestation’sfuelhose,ordedicatedstationventlinepriortorefueling.SeeSection 5.6—VentingformoreinformationonventingLNGtanksforfueling.
Vent-to-Atmosphere Valve Locatedinsidethetankshroudontheright-handside,thisvalvecontrolstheventingofexcesstankvaporsafelythroughthevehicle’sventstacktothe
atmospherewhenvent-to-stationisnotavailableorpossible.SeeSection 5.6—VentingformoreinformationonventingLNGtanksforfueling.
Service ONLY Valves (to be used by qualified personnel only)
Liquid Drain ValveDrainsLNGfromthetankpriortoatankorpumpserviceorrepair.
Accumulator High-Pressure Gas Shut-Off Valve Locatedneartheaccumulator,thisvalveisolatesthehigh-pressuregasintheaccumulatorduringdownstreamgassystemmaintenance.Thisvalveshouldonlybeoperatedbytrainedrepairpersonnelusingvalvelock-outproceduresduringmaintenance(seeFigure 5).
AdetaileddescriptionofthevalvesandtheirfunctionsisinSection 4.3—Pressure Safety Devices.
WARNING! The Westport LNG System contains high-pressure
gas, liquid, and cryogenic fluids—even when the truck is turned off. No unauthorized or untrained person should EVER attempt maintenance or repairs on a
Westport LNG System truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or
cryogenic burn injuries could occur.
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Figure 4—LNG tank and plumbing (other configurations possible)
Secondary tank relief valve (2,200 kPa / 315 psi)
Vent-to-station valve
Manual emergency shut-off valve
LNG pump
Vent-to-atmosphere valve
Primary tank relief valve (1,600 kPa / 230 psi)
To vent stack
Water drain
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1.4.3 Outside the Engine Bay (continued)
• Westport LNG System Control Consistsoftwoon-boardelectronicsmodulesconfiguredinaparent-childrelationship.ThesemodulescontroltheWestportLNGSystemincluding:HPDIinjectors,LNGpump,andengineparameters.Modulesaremountedonthechassis,orbeneaththecabanddisplaymessagesontheWestportLNGSystemMonitor.
Figure 5—Westport LNG System Controllers, high-pressure accumulator, and associated plumbing (other configurations possible)
Westport LNG System Controllers
Accumulator high-pressure gas
shut-off valve
High-pressure gas filter
High-pressure accumulator
• High-Pressure AccumulatorThehigh-pressureaccumulator,containingCNGathighpressure,islocatedbetweentheframerails,orbehindthecab.ItisusedtoreducegaspressurepulsesinthesystemintroducedbytheLNGpump.High-pressuregasisdeliveredfromtheaccumulatortotheengineforcombustion.
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Figure 6—Vent stacks, filter, and drain port (other configurations possible)
Vent stacks
Vent stack filter
Drain port
• High-Pressure Gas Filter Mountedneartheaccumulator,thehigh-pressuregasfilterprovidesprimaryfiltrationforCNGenteringtheengine.
• Gas Vent Stacks Theventstacksaresmallpipesthatrunupalongthebackofthecab.Theyserveasawayforexcessgastoescapesafelyupandawayfromthetruck.
Therearetwoventstacks:oneventstheLNGtanks;theotherventstheenginegasrail,FCM,andaccumulatorpressure.Thesecondventstackisequippedwithafilteranddrainport.SeeSection 6.1—Maintenance Schedulesfordrainintervals.
• Remote Fill Panel Equippedonsomemodels,thispanelallowsmulti-tanksystemstobefueledfromonelocation.Theremotefillpanelisequippedwithventportsandagroundinglug(seeFigure 7).Formoreinformationonfueling,pleaseseeSection 5—Safe LNG Truck Fueling.
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1.4.3 Outside the Engine Bay (continued)
Figure 7—Remote fill panel (if equipped)
Fuel nozzle
Vent line receptacle
Ground lug
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2. Pre-Trip InspectionTheWestportLNGSystemrequiresregularmonitoringandmaintenancetoensuremaximumperformanceandsafety.Beforestartingyourtrip,completethepre-tripinspectiondescribedinthefollowingsectionsinadditiontoyournormalrequiredtruckwalk-around.Thereisasamplepre-andpost-tripinspectionsheetinAppendix A—Daily Log Sheetofthismanual.
WARNING! The Westport LNG System contains high-pressure
gas, liquid, and cryogenic fluids—even when the truck is turned off. No unauthorized or untrained person should EVER attempt maintenance or repairs on a
Westport LNG System truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or
cryogenic burn injuries could occur.
2.1 CheckInsidetheCab
WARNING! Naturalgasiscolorlessandodorless.Youmustcheck
the operation of the Gas Detection Monitor and listen for soundsofaleak.Ifyoudetectsignsofaleak,seeredoryellowlights,hearagasalarm,orcannotseethegreenpowerlightonthedetector,doNOTenteroroperatethe
truck.Notifytheshopfromoutsidethetruck.
Beforeenteringthetruck,checkthegasdetectionmonitorlocatedinthedashboard(seeFigure 2).Section 3.3—Gas Detection Monitordescribesthefunctionofthegasdetectionindetail.
Before entering the cab:
1. Check for a green power light on the Gas Detection Monitor.Ifthegreenlightisoff,gasdetectionhasbeendisabled—DoNOTstartthetruck;notifytheshop.
2. Check for red or yellow lights on display.Ifredoryellowlightsareon,thisindicatesaleak—DoNOTstartthetruck;notifytheshop.
3. Listen for an alarm.Ifyouhearanalarm,thisindicatesaleak—DoNOTstartthetruck;notifytheshop.
4. Listen for an audible (hissing) noise; it may indicate a leak—DoNOTstartthetruck;notifytheshop.
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2.1 CheckInsidetheCab(continued)After entering the cab:
1. Checktheoperationofthegasdetectorbypressingthe[TEST]buttononthegasdetectionmonitor.Formoreinformationoncheckingandtestingthegasdetectionmonitor,seeSection 3.3—Gas Detection Monitor.
2. Checkthatrequiredsafetygearforfuelingisinplace,ifyourefuelthetruckyourself(seeSection 5.1—LNG Fueling Safety Equipment).
3. Turnkeytothe[ON]positionandchecktheOEMdieselfuellevelgaugetoensurethatyouhavediesel.Section 6.2.6—Diesel Fuel Specificationcontainsinformationondieselfueltypeandexpectedusage.
4. Withthekeyinthe[ON]checkLNGfuellevelsdisplayedontheWestportLNGSystemMonitor.Section 6.2.1—LNG Composition SpecificationscontainsinformationonLNGFueltype.
5. Turnkeytothe[OFF]positiontocompletenextchecks.
2.2 CheckInsidetheEngineCompartmentWiththeengineoff,inspecttheenginebayforanyleakssuchasdieselfuel,engineoil,hydraulicfluid,andgasleaks.Listenforthesoundofaleak.Checkthefollowing:
Hosesandfittings
Drainalldieselfuel-waterseparators
Drainventstackfilter
High-pressuredieselpumpandtheconditionofthebelt
Hydraulicpumpandfittings
FCM
Hydraulicreservoir/powersteeringlevel
Hydraulicoilcoolerisunblockedandfreeofdebris
Thefrontandsidesofengineforoilleaks.
Notethelocationofanyleaksorabnormalitiesandhavethemrepairedbyaqualifiedtechnicianbeforeoperatingthetruck.
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Safety cap
Figure 8—Secondary relief valve
Normaltankpressurecanvarybetween205kPaand1,600kPa(30and230psi).Adviseaqualifiedtechnicianifthepressurevariesaboveorbelowthenormalrange,orifthetruckventsfrequently.
Ifyounoticemorefrostingthanusual,itmayindicatealeak.Notethefrostedareaandreportittotheshopimmediately.Anyleakmustberepairedbeforestartingthetruck.
Ventingwillproduceanaudiblehissingsoundfromtheventstacks.Reportuncontrolledventingtotheshop,asrepairsmayberequired.
2.3 CheckOutsidetheEngineCompartmentInspecttherestoftheWestportLNGSystemcomponentsforexternaldamage,leaks,ortampering.Lookto:
Checkthehigh-pressuregasfilterlocatedneartheaccumulatorforleaksordamage
InspecttheLNGtankandvalvesforabnormalfrostoraudibleleaks
Checktheventstackforexcessiveventing
Checkthatthesafetycapispresentonthesecondaryreliefvalve(seeFigure 8)
Makesurevent-to-stationvalveisclosed.
Note:theplasticsafetycapinstalledonthesecondaryreliefvalvekeepsmoistureanddebrisoutofthevalve.However,italsoindicatesifthesecondaryreliefvalvehasbeenused.Theabsenceofthecapindicatesapossiblemalfunctionoftheprimaryreliefvalve.Alwayscheckandreporttotheshopifthesecondaryreliefvalvecapismissingbefore startingyourtrip(seeSection 4.3.1—Automatic Relief Valves).
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2.3 CheckOutsidetheEngineCompartment (continued)
Remember! The reading on the LNG tank pressure gauge has
NO correlation to amount of fuel in the tank.
WARNING! Iftankpressurereadszero,notifyshop,
asthismayindicatealeak.
WARNING! The Westport LNG System contains high-pressure
gas, liquid, and cryogenic fluids—even when the truck is turned off. No unauthorized or untrained person should EVER attempt maintenance or repairs on a
Westport LNG System truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or
cryogenic burn injuries could occur.
PRE-TRIP SUMMARY
Checkgasdetectionmonitorstatusbeforeenteringcab.
Testgasdetectionmonitoroperationbypushing[TEST]button.
Checkenginecompartmentcomponentsforleaks,tampering,anddamage.
Checkforrequiredfuelingsafetygear,ifplanningtorefuelyourself.
CheckLNGanddieselfuellevels.
CheckLNGtanksandframe-mountedcomponents.
Checksecondaryreliefvalvecap.
Checkvent-to-stationvalveisclosed.
Checkhydraulicoilcoolerisunblockedandfreeofdebris.
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3. Starting and DrivingAWestportLNGSystemequippedtruckisdrivenexactlylikeanequivalentdiesel-poweredtruck.Thepowerbandandshiftingpointsaresimilar.TheonlydifferencewhiledrivingistochecktheWestportLNGSystemMonitor.Section 3.2—Westport LNG System MonitorandSection 3.3—Gas Detection Monitorcovertheinstrumentationindetail.
3.1 Starting the Engine
CAUTION!The user of ether as a cold climate starting aid is not recommended for the Westport LNG System and may
lead to component damage.
The engine should be started only after a complete pre-trip inspection.ThestartingprocedureofaWestportLNGSystemtruckisthesameasaregulardieseltruck.Tostartthetruck,turnthekeytothe[START]positionandcranktheengineuntilitfires.SeeSection 7—Diagnostics and Troubleshootingiftheenginehasproblemsstarting.
TANK 1 TANK 1 TANK 2
Figure 9—Westport LNG System Monitor (single and dual tank systems shown)
Note:ifthereareanymessagesontheWestportLNGSystemMonitor,followtheinstructionsshownonthedisplay.Whenyoufirststartthetruck,themessage“PleaseWait…”isshownuntilthecoolantissufficientlywarmedand/orthehigh-pressureaccumulatorisfullycharged.Whilethismessageisshown,youcanbobtailthetruck(withnoloadortrailer)aroundtheyardtoamaximumof6mph(10km/h).Anaudiblealarmissoundedwhentruckexceedsspeedlimit.SeeSection 3.2—Westport LNG System Monitorformoreinformation.
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3.1 Starting the Engine (continued)
CAUTION!Exceeding speed limit while “Please Wait...” message
is displayed may cause Westport LNG System components to freeze up.
START-UP SUMMARY
1. Turnignitiontothe[START]positionandcrankengineuntilitfires.
2. WaitfortheWestportLNGSystemMonitortoshowanormaldrivingscreen.
3. Donotexceed10km/h(6mph)when“PleaseWait…”messageisdisplayed.
4. Checkcontrolsandgaugesbeforebeginningyourtrip.
5. Ifnofaultsormessages,youcanbegintodrive.
3.2 Westport LNG System MonitorTheWestportLNGSystemMonitordisplaysmessagesaboutthestatusoftheWestportLNGSystem.Themainscreenhastwowindows.
TANK 1
LNG fuel tank level meter (showing 5/8 full)
Disabled pump indicator (pump not working)
Cold gas discharge temperature indicator (coolant temperature too low, usually accompanied with “Please Wait...” message
Figure 10—Westport LNG System Monitor (top window summary, bottom window message example)
3.2.1 TopWestportLNGSystemDisplayWindow
Thetopwindowshows:
• LNG fuel tank level meter and LNG pump icon
• Disabled LNG pump indicator-(Xthroughthepumpicon)
• Cold gas discharge temperature indicator-(snowflakeunderthepumpicon)
17
Fortrucksequippedwithmultipletanks,thetankiconwillflashtoshowwhichtankfuelisbeingdrawnfrom.Undernormalconditions,thisshouldalternatebetweentanks.
3.2.2 BottomWestportLNGSystemDisplayWindow
TheLNGSystemhasthefollowingoperatormessages:
Table 1—Westport LNG System Monitor messages
Message Alarm Cause ActionPlease Stop Engine…
YES Significant engine issue
Pull over, stop engine, and call shop/service
Check for CNG Leak
YES Possible high-pressure gas leak
Pull over, stop engine, and call shop/service
Prepare to Stop YES Loss of gas supply Prepare to pull over and stop
Please Wait… YES* Coolant not sufficiently warmed
Wait before driving truck over 10 km/h (6 mph)
Tank 1/2/3 shut-off is closed
NO Manual emergency shut-off valve (if equipped) is closed
Check with qualified LNG System technician if truck is ready for service
LNG Tank 1/2/3 is empty
NO No LNG fuel in tank Refill LNG tank
Check ECU Next Stop
NO Active fault code stored in ECU
Advise shop of message after return from trip
On Diesel – XXX Seconds Remaining
NO Possible fault in LNG System or no LNG fuel in tank
Engine running on diesel; pull over, wait for gas pressure build up, and call shop/service
* alarm sounds if speed limit is exceeded
3.3 Gas Detection MonitorWestportLNGSystemtrucksareequippedwithnaturalgassensorsmonitoringtwozones:
Table 2—Gas detection zone assignment
Area Sensor LocationCab On A-pillar
Engine bay Mounted on bulkhead
Cab
Engin
e Bay
GASCONCENTRATION:
SilenceEngaged
RelayEngaged
Pushto
Silence
RelayReset
Pushto
Test
Figure 11—Gas detection monitor (if not as shown, refer to OEM supplemental documentation)
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3.3 Gas Detection Monitor (continued)Twolightscorrespondwitheachzoneonthedisplay:
Table 3—Gas detection interpretation
Light Alarm Meaning ActionOFF NO No gas leak detected None, normal conditions
Yellow (Trace)
NO Indicates a trace gas leak [20–50% of lower explosive limit (LEL)] near corresponding location
Continue to drive
Monitor gas detector for change to alert
Report to shop
Repair leak before next trip
Red (Alert)
YES Indicates significant gas leak [>50% of LEL] near corresponding location
Pull over
Shut off engine and all emergency shut-off valves (if safe to do so)
Notify shop
Do NOT operate truck until repair is done
If “Cab”–exit and do not return to cab. Unroll the window if safe to do so
If “Engine bay”–open hood if safe to do so
Thesensorfaultlightsshowifasensorisnotworkingcorrectly.Itisrecommendedthatthegasdetectionmonitorbetestedduringthepre-tripinspectionbypressingthe[PUSHTOTEST]button.Reportanyproblemstotheshop.
Cab
Engin
e Bay
GASCONCENTRATION:
SilenceEngaged
RelayEngaged
Pushto
Silence
RelayReset
Pushto
Test
Figure 12—Gas detection monitor – [PUSH TO TEST] button
WARNING! Naturalgasiscolorlessandodorless.Youmustcheck
the operation of the gas detection monitor and listen for soundsofaleak.Ifyoudetectsignsofaleak,seeredoryellowlights,hearagasalarm,orcannotseethegreenpowerlightonthedetector,doNOTenteroroperatethe
truck.Notifytheshopfromoutsidethetruck.
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3.4 TurningtheTruckOffWhenyourtripiscomplete,lettheengineidlefor2minutesthen,turnthekeytothe[OFF]position.
YoumaynoticeventingintheVentStackbehindthecab.Itisnormal forthefuelsystemto vent a small amount of gastotheatmosphereaftershutdown.Theventingshouldnotlastmorethan5seconds.Ifventingpersists,notifytheshop.
3.5 Post-Trip InspectionThepost-tripprocedureissimilartothepre-tripinspection.Inparticular:
1. CheckandrecordtheLNGtankpressure.
2. Lookforleaks.
3. EnsureWestportLNGSystemcomponentsaresecurelymounted.
4. Checksecondaryreliefcaponeachtank(seeFigure 8).
5. Itisimportantthatyoucheckthetankpressure.Thetankpressurecouldrise275kPa(40psi)eachdaywhenthetruckisparked(notused).Ifthetankpressureconsistentlyincreasesmorethan275kPa(40psi)perday,reportittotheshop,astheremightbeaproblemwithyourtank.
3.6 Exhaust Aftertreatment ConsiderationsWestportLNGSystemtrucksmaybeequippedwithanOEMintegratedCumminsParticulateFilter,whichhasitsownoperationalandsafetyconsiderations.PleaserefertoOEMdocumentationontheDPFandexhaustaftertreatmentsystemformoreinformation.
WARNING! Regeneration,aspartoftheexhaustaftertreatment
system,cancauseexhaustgasandtheexhaustsystemsurfaces to get hot enough to burn people and ignite or burn common materials. See OEM documentation for
moreinformationonassociatedhazards.
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3.7 Parking—GeneralandforMaintenance
WARNING! YOU MUST PARK OUTSIDE
Neverallowthetrucktoventorleakinanenclosedspace.Thegaswillriseandcollectinareaswherethere
may be an ignition source. An explosion could result.
Parkingoutsideismandatory.Remember,thetankreliefvalveswillreleaseatapproximately1,600kPa(230psi).Itisnormalforthetankpressuretoriseandautomaticventingtooccurthroughtheventstacks.
Indoorparkingoroperationmaybeallowedprovidedthefacilityisproperlyequippedandthetruckisappropriatelypreparedtopreventanaccumulationofnaturalgasinacombustiblemixture.TruckandfacilitypreparationaredictatedbynationalcodessuchasNFPA30Aandotherlocalrulesandregulations.Alwayscheckwiththeforemantoseeifyourfacilityhastheappropriateequipment.
Neverparkindoorsformaintenancewithoutcompletingathoroughleakinspectionofthetruck.
Ifindoorparkingisrequiredformaintenance,contactyourlocalWestportServicerepresentative(seeAppendix C—Contact Information)todiscussupgradestoyoubuildinganddevelopshopproceduresspecifictoyourfacility.
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4. Westport LNG System Safety PrecautionsThissectionprovidesinformationaboutthesafeoperationofyourWestportLNGSystemtruck.
4.1 FuelsTheWestportLNGSystemcontainsLNG,highpressurenaturalgasvapor(CNG),lowpressurenaturalgasvapor(tanksonly),anddieselfuel.Thepresenceofthesecompoundsrequiresunderstandingofsafeuseandhandlingofthesematerials.
Thefollowingsectiondescribestheliquidsandgasesyouwillencounterandthestepsyoushouldtaketoensuresafeoperationandhandling.MoreLNGinformation,suchastheMaterialsSafetyDataSheet(MSDS),isinSection 8—LNG Properties and Handling.
4.1.1 Liquefied Natural Gas (LNG)
Description: Storedatapproximately-130°Cto-165°C(-202°Fto-265°F),naturalgaswillnotigniteasaliquidbutwilligniteasvapor.LNGturnsintonaturalgasvaporsoonafterleavingthesystem.Itisclear,odorless,andnon-toxicasaliquidoragas.
WARNING! LNG is a cryogenic (extremely cold) fluid. Avoid
contactwithliquidandplumbing.Freezingburnsandlacerationscouldoccur.WearappropriatePPEwhen
workingaroundtheLNGtankorplumbing.
4.1.2 Natural Gas Vapor and CNG
Description: Flammablewhenmixedwithairandagasconcentrationbetween5–15%.Naturalgasvaporisignitablebystaticdischarge,lighterthanair,odorless,andnon-toxic.Naturalgasisasimpleasphyxiant.CNGishigh-pressurenaturalgasvapor.
WARNING! Neversmokewhilefuelingorexposenaturalgasto
sparksorflames.Naturalgasisflammablewhenmixedwithair.Neverallowtrucktoventinanenclosedspace.
WARNING! Natural gas is lighter than air and can accumulate in enclosedspaces,suchasunderthehoodorunderawnings.Ifthereisanignitionsourceanexplosioncouldresult.Neverallowthetrucktoventinanenclosedspace.Parkingoutsideismandatory.
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4.1.2 Natural Gas Vapor and CNG (continued)
WARNING! Natural gas is colorless and odorless. You must checktheoperationofthegasdetectionmonitorandlistenforsoundsofaleak.Ifyoudetectsignsofaleak,seeredoryellowlights,hearagasalarm,orcannotseethegreenpowerlightonthedetector,doNOTenteroroperatethetruck.Notifytheshop
fromoutsidethetruck.
WARNING! Do not stay in a natural gas vapor cloud. Natural gas
displaces oxygen and can cause asphyxiation.
WARNING! Naturalgasisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.Westportrecommendsnotsmokingwhileoperatinga
WestportLNGSystemtruck.
WARNING! Releaseofhighpressuregascanbreakorpropel
componentswithexplosiveforce.Donotturnvalvesyouareunfamiliarwith.
4.1.3 Diesel
Description: Strawcoloredtodyedliquid,withacharacteristicpetroleumodor.Stableundernormalambientconditionsoftemperatureandpressure.Flammableliquidandvapor.Vaporisheavierthanairandcancauseflashfire.Dieselisknowntocausesevereskinirritationandisanaspirationhazardifswallowed.Canenterlungsandcausedamage.
WARNING! Diesel is flammable in liquid or vapor form. Keep awayfromheat,sparks,flames,staticdischarge,
or other sources of ignition. Vapor may travel considerabledistancestoasourceofignitionwheretheycanignite,flashback,orexplode.Maycreatevapor/airexplosionhazardindoors,inconfined
spaces,outdoors,orinsewers.Vaporsareheavierthanairandcanaccumulateinlowareas.
23
4.2 High Pressure
WARNING! TheWestportLNGSystemcontainshigh-pressuregas,liquid,andcryogenicfluids—evenwhenthetruckis
turnedoff.NounauthorizedoruntrainedpersonshouldEVER attempt maintenance or repairs on a Westport
LNGSystemtruck.Donotturnvalvesyouareunfamiliarwith.Serioushigh-pressureblastorcryogenicburn
injuries could occur.
TheWestportLNGSystemoperatesatpressuresupto33MPa(4,800psi).HighpressureispresentintheLNGtankandmostoftheCNGplumbing,evenaftertheengineisturnedoff.Thesystemisdesignedtosafelyhandlethesehighpressuresandisequippedwithpressuresafetydevices(seeSection 4.3—Pressure Safety Devices).
4.3 Pressure Safety DevicesTheWestportLNGSystemisequippedwithsafetydevices:automatic relief valvesandmanual valves.
4.3.1 Automatic Relief Valves
Table 4—Automatic relief valves and devices
Valve Location FunctionPrimary LNG tank pressure relief valve
Inside the vent manifold (see Figure 13)
If pressure in the tank exceeds 1,600 kPa (230 psi), the valve opens automatically to relieve pressure through the vent stack.
Secondary LNG tank pressure relief valve
Below the LNG pump (see Figure 13)
Backup relief valve in case of primary relief valve failure. Opens at 2,200 kPa (315 psi), and is equipped with blow-off cap which may warn of primary malfunction.
LNG pump pressure relief valve (if equipped)
On the LNG pump (see Figure 13)
Protects the system from over-pressure, relief set at 38 MPa (5,500 psi) and discharges into LNG tank.
Accumulator pressure relief valve
Near the high-pressure gas filter (see Figure 14)
Pressure activated valve—protects the accumulator from over-pressure. Relief is set at 37 MPa (5,400 psi) and discharges externally towards the ground.
Accumulator pressure relief device
On the accumulator manifold (see Figure 14)
Temperature activated device.—protects the accumulator from over-pressure. In the event of fire or heat exceeding 109 °C (228 °F), discharges externally towards the ground.
Diesel pressure relief device
On the FCM inside the engine bay
Protects the engine from diesel over-pressure, returns excess diesel fuel into the diesel tank.
24
Secondary LNG pressure relief valve (set at 2,200 kPa / 315 psi)
inspect presence of cap daily
Figure 13—LNG tank shroud automatic pressure relief valves (other configuration possible)
Primary LNG tank pressure relief valve
(inside vent manifold, set at 1,600 kPa / 230 psi)
LNG pump pressure relief valve (38 MPa / 5,500 psi)
Figure 14—High-pressure accumulator plumbing (other configurations possible)
High-pressure accumulator shut-off
(service only)
Accumulator pressure relief device—relieves at or above
109 °C (228 °F)
Accumulator pressure relief valve (37 MPa / 5,400 psi)
4.3.1 Automatic Relief Valves (continued)
25
4.3.2 Manual Valves
TheLNGtankshroudcontainsasmanyasfourmanualvalvesusedprimarilyduringmaintenanceandserviceofthetruck.Valvesmustbeoperatedonlybytrainedtechniciansandpersonnel.Thefollowingfigureandassociatedtableoutlinethelocationandfunctionofvalveoperation.
Table 5—Manual valves
Valve / Location FunctionManual emergency shut-off valve (if equipped)Red handle at left side of the LNG pump* (see Figure 15)
¼ turn valve. Isolates gas pressure within the tank from the engine bay. Valve must be open for truck to run on natural gas. If closed, warning message “Tank Shut-off Closed” shows on driver display.
Vent-to-station valveBelow and left of LNG pump* (see Figure 15)
Hand turn valve. When open, valve allows vapor to flow from LNG tank through fill hose, and back to the fueling station. Valve is normally closed and should only be open after filling hose or dedicated vent line is secured. WARNING: Vent-to-Station valve must be closed after fueling.
Vent-to-atmosphere valveBelow and right of the LNG pump* (see Figure 15)
Hand turn valve. When open, valve allows flow of vapor from the LNG tank into the atmosphere via the vent stack. The valve is normally closed.
Liquid drain valve (service only)*(see Figure 15)
Hand turn valve (requires special service tool). Drains LNG from the tank for service or maintenance.
High-pressure gas accumulator shut-off valve (service only)(see Figure 14)
¼ turn valve. Isolates high-pressure gas in the accumulator for service or maintenance. To be used only by trained Westport LNG System personnel in conjunction with lock-out procedures.
FCM vent valve (service only)Inside the engine bay located on the FCM
Hand operated valve. Vents FCM pressure for service or maintenance.
* location indicated on tank shroud labelFigure 15—LNG tank shroud manual pressure relief valves (other configurations possible)
Road side tank fill port
Vent-to-station valve
Emergency shut-off valve LNG pump
Vent-to-atmosphere
valve
Liquid drain valve (service only)
LNG tank vapor
pressure gauge
26
4.3.2 Manual Valves (continued)
WARNING! The Westport LNG System contains high-pressure
gas, liquid, and cryogenic fluids—even when the truck is turned off. No unauthorized or untrained person should EVER attempt maintenance or repairs on a
Westport LNG System truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or
cryogenic burn injuries could occur.
WARNING!LNG is a cryogenic (extremely cold) fluid. Avoid
contactwithliquidandplumbing.Freezingburnsandlacerationscouldoccur.WearappropriatePPEwhen
workingaroundtheLNGtankorplumbing.
WARNING! YOU MUST PARK OUTSIDE
Neverallowthetrucktoventorleakinanenclosedspace.Thegaswillriseandcollectinareaswherethere
may be an ignition source. An explosion could result.
CAUTION!The tank vapor pressure could rise 275 kPa (40 psi)
per day when the truck is parked.
4.4 GasLeaksClassificationandResponseItisimportanttoinspectthetruckdaily,asdescribedinSection 2—Pre-Trip Inspection.Youmaydetectaleakbyhearingahissingsound,noticingunusualfrostoriceaccumulation,orbeingalertedbythegasdetectionmonitor.
Responsetogasleaksdependsontheleakclassification.Therearethreeclassificationsofleaks(listedindecreasingseverity).
Severe:
• UncontrolledspillorsprayofLNG
• Aleakwhichresultsinalargevaporcloud
• Anyleakwherethevehicleislocatedinaplacewheregasmayaccumulate
• Anyleakwhereasourceofignitionisincloseproximitytothevehicle
Response:seeSection 4.5—Emergency Response
Significant:
• On-boardgasdetectorisinalertbutnoother“Severe”conditionsaremet
• Detectedgaslevelisgreaterthan50%oftheLowerExplosiveLimit(LEL)
Response:seeSection 3.3—Gas Detection Monitor: Table 3—Gas detection interpretation
27
Trace:
• On-boardgasdetectorisintracealarm,butnoother“Severe”or“Significant”conditionsaremet
• Detectedgaslevelisbetween20%and50%oftheLEL
Response:seeSection 3.3—Gas Detection Monitor: Table 3—Gas detection interpretation
WARNING! Naturalgasiscolorlessandodorless.Youmustcheck
the operation of the gas detection monitor and listen for soundsofaleak.Ifyoudetectsignsofaleak,seeredoryellowlights,hearagasalarm,orcannotseethegreenpowerlightonthedetector,doNOTenteroroperatethe
truck.Notifytheshopfromoutsidethetruck.
4.5 Emergency ResponseDuetothepresenceofLNGandCNGon-board,additionalsafetyprecautionsmustbetakenwhenrespondingtoanemergencyinvolvingaWestportLNGSystemtruck.Westportconsiders(butdoesnotlimit)thefollowingsituationsasemergencies.
Emergency Situations
• Fireon-boardthevehicle
• UncontrolledSeverenaturalgasleak
• AnyothercircumstancerequiringassistancefromEmergencyPersonnel
Emergency Response
Intheeventofanemergency,followstandardsafetypracticestoensureyourownpersonalsafetyandthesafetyofothers,and
1. Findasafespottopullover
2. Turnofftheengine
3. Turnoffmanualemergencyshut-offvalve(ifequipped)andaccumulatorshut-offvalve(ifsafetodoso)
4. CallemergencyrespondersandinformthemthatLNGandCNGareon-board
5. Clearandsecurethelargestpracticalperimeter
6. Informshop/dispatch
SeeSection 8.4 – Sample LNG MSDS,formoreinformationonemergencymeasureswithrespecttoLNG.IfyouhaveanyfurtherquestionsorconcernspleasecontactWestportService(seeAppendix C—Contact Information).
28
5. Safe LNG Truck FuelingWARNING!
The following procedure is a guideline only and does not replace proper training. Due to the variety of fueling stations, you MUST receive training to your specific LNG
fueling station.
FuelingofLNGtrucksishighlycontrolledandthereforequitesafe.LNGstationstypicallyhavemoresafetyfeaturesthanotherfuelfillingstations.Thefollowingprecautionsminimizeharmintheeventofasafetyincident.Followtheprocedurestoensurethatthesafetyofthefuelingprocessismaintained.
5.1 LNG Fueling Safety EquipmentBelowisarecommendedlistoftheminimumpersonalprotectiveequipment(PPE)requiredforLNGfueling.ItisrecommendedthatthisequipmentiscarriedonboardaWestportLNGSystemtruckatalltimes.Checkwithyourfleetand/orLNGproviderastheymayhaveadditionalrequirements.
5.1.1 Recommended Personal Protective Equipment (PPE)
• Fullfaceshield
• Heavyleathergloveswithlongcuffs(weldingorsimilarthicknesswithcuffstothemid-forearm)
• Fire-retardantraincoat
• Longpantsortrousers
• Closedtoeleathershoesorboots
Notethattheseareminimumrecommendations.Yourfuelingstationorfleetmayhavetheirownrequirements.
5.1.2 TruckEquipment
• ABC-ratedMultipurposeDryChemicalfireextinguisher—2.3kg(5lbs)minimum*
• Emergencytrianglesorcones
• Flashlight(forpre-andpost-tripinspections)
*FormoreinformationonextinguishingfiresandotheremergenciesinvolvingLNGseeSection 8.4 – Sample LNG MSDS.
29
5.2 LNG Fueling BasicsLNGfuelingreliesonthetransferofnaturalgasinliquidform.BecauseLNGispressurizedandcontainedinaclosedtanksystem,youcannotphysicallycheckthelevelofLNG,(suchaslookingthroughthefillopeningofadieseltank).YoumustrelyontheWestportLNGSystemMonitorfuelgaugeandthestationdispensertoestimatetheamountofLNGpresentinyourtank.
Astheliquidpassesthroughthefuelinghoseandintothetank,someoftheliquidwarmsandconvertstovapor.ThisstatechangefromliquidtogasincreasesthevaporpressureinsidetheLNGtank.Thetankpressuregaugeindicatesthisvaporpressureanddoes notindicatetheamountofliquidinsidethetank.TheWestportLNGSystemreliesonlyontheliquidnaturalgas,notthevapor,unlikeothernaturalgasenginetechnologies.
WithvaryingLNGtankpressure,thefuelingprocedurecanchangeanddependslargelyonstationtypeandfuelcondition(temperatureandpressure).ThebasicrulesofLNGfuelingareconsistent.Detailedfuelingproceduresspecifictoyoursystemplumbing(suchasasingleversusmultipletanksystems),aswellastheparticularLNGstationusedatyournormalfuelinglocation,iscoveredinyourfuelingtraining.Thefollowingarebasicrules,whichmakefuelingeasierandshortenyourtimeatthepump.
Basic Rules for LNG Fueling:
1. Stay safe!
• Followstationandtrucksafetyrulesandinspectyourequipmentbeforeuse.
• BefamiliarwiththeEmergencyShut-Down(ESD)buttonsincaseofanemergency.
• WearyourPPEandgroundthevehiclewithastationgroundingcable.
• Parkthetruckwithparkingbrake[ON],engineoff,andkeyinthe[OFF]position.
• Checkthattherearenoignitionsourcesnearby(openflame,smoking,runningengines,etc.).
WARNING! Naturalgasvaporisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.WestportrecommendsnotsmokingwhileoperatingaWestportLNGSystemtruck.
30
5.2 LNG Fueling Basics (continued)Basic Rules for LNG Fueling (continued):
2. Vehicle LNG tank pressure must be less than station output pressure.
• Pressurecontrolisnotalwayspossible,asitdependsonfrequencyoftruckuseandfuelcondition.Factorssuchasplanningyourfuelingandventingbacktostationcanhelpwithpressurecontrol(seeSection 5.7—Minimizing Venting and Fuel Loss).
• Youcanstillfuelifthetankpressureexceedsthestationpressurebecausethestationisequippedwithapump,whichforcestheLNGintothetank;howeverthefillingprocessmaytakelongertocomplete.
• Minimizeventingtoatmosphere,asthisactionreleasesmethanegaswhichisharmfultotheatmosphere.
3. Use compressed air to dry the fueling hose and LNG tank receptacle.
• Moistureinsidethenozzleandfuelingreceptaclescancausefuelingcomponentsandvalvestofreeze.
• LNGmaysprayduringfuelingasaresultofpoorcomponentfitandoperation.
• Frozenmoistureinthenozzleandfuelreceptaclecancausedisconnectionproblemspost-fueling.(seeSection 7—Diagnostics and Troubleshootingformoreinformation)
4. Cool down your LNG fueling hose prior to filling.
• ColdLNGstationplumbingcangreatlyimproveyourfill,byavoidingtherapidstatechangethathappenswhencoldLNGpassesthroughawarmhose.
• Usetankvent-to-stationvalve,ifventingbacktothestation,asitaidsincoolingthefillhose(Section 5.6.1—Venting to Station outlinesthisprocedure).
5. Know your truck.
• Basedonyoursupervisedfillsandtraining,knowhowmuchfuelyoushouldbetakingonboard.
• RefertotanksizechartinSection 6.2.8—Usable LNG Tank SizestodeterminethemaximumamountofLNGatankcanhold.
Remember!The reading on the LNG tank pressure gauge has
NO correlation to amount of fuel in the tank.
5.3 Incident ReactionYoumusthaveproperLNGfuelingtrainingtooperateanyLNGrefuelingstation.Trainingincludesinstructionsonwhattodoifthereisanemergencyoranincident.FollowthestepsoutlinedinyourspecificLNGEmergencyResponsePlan.Ifyouneedmoreinformation,contactyourlocalLNGstationrepresentative.
31
5.4 Pre-FuelingYoumusthaveproperLNGfuelingtrainingspecifictoyourLNGstation.ThistrainingdetailsthespecificprocesstofollowbeforefuelinganLNGtank.Usethefollowingpointsasaguidelinebeforefuelingyourtruck:
1. Verifythatanescaperouteisclearandunlockedforallfuelingpersonnel.
2. VerifylocationandreadinessofESDsandtheEmergencyPhone.
3. Inspectsafetyequipmentfordamage,readiness,andfit(fireextinguisherandPPE).
4. Visuallyinspectstationandtruckfuelsystempipingforleaksandbringanyleakstotheattentionofthestationprovider.
5. Neverleaveavalveopenandunattended.
6. Notifysitepersonnelifrequired.
5.5 LNG Fueling
WARNING!The following procedure is a guideline only and does
not replace proper training. Due to the variety of fueling stations, you MUST receive training to your specific LNG
fueling station.
1. Parkthetruckintheproperpositionforfueling.Thetransferhoseandgroundcablemustreachthetruckorremotefillpanel(ifequipped)withoutstretching.
2. Setthetruckbrakesandmakesurethetruckisoutofgear.
3. Turnofftheignition.
4. Recordnecessarydatainthefuelinglogbookandthetrucklogbook.
5. PutonyourPPE.EnsurethatanyoneassistingyoualsowearsPPE.
6. AttachgroundclamptotheLNGtankorremotefillpanelifequipped(seeFigure 16—LNG Tank ground clamp attachmentandFigure 17—Remote Fill Panel attachments).
7. Ifyouarefuelingatankthathasbeenemptiedforservicereasons,getanyspecialinstructionsfromaWestportLNGSystemtrainedtechnician.
8. Inspect,clean,anddrythefuelnozzle.Usepressurizedairtoremovedirtandicefromnozzleface.
9. Doanynecessaryventingoffueltanks(seeSection 5.6—Ventingformoredetails).
10.Closeventvalves.
11.RemovecaponLNGtankorremotefillpanel(ifequipped).Inspect,clean,anddryfuelconnector.Usepressurizedairtoremovedirtandicefromconnectorface.
12.ConnectfuelingnozzletoLNGtankorremotefillpanel(ifequipped).
13.Startfuelingbypressingthestation[START]button.
32
5.5 LNG Fueling (continued)14.Thestationshouldstoponcethetankisfull.Confirm
thetankisfullbycheckingtheWestportLNGSystemMonitorwiththekeyinthe[ON]position.
15.CarefullydisconnectthefuelnozzleandinstallthedustcaponthefillhoseandLNGtankorremotefillpanel(ifequipped).
16.Returnhoseandgroundclamptothefillingstation.
17.Finishrecordingnecessarydatainthefuelinglogbookandthetrucklogbook.
18.Removeandstowallsafetyequipment,beingcarefultobrushanyiceoffoftheglovesbeforeremovingthemfromyourhands.
WARNING! Naturalgasvaporisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.WestportrecommendsnotsmokingwhileoperatingaWestportLNGSystemtruck.
Ground lug
Figure 16—LNG tank ground clamp attachment
Ground lug
Vent line receptacle
Figure 17—Remote fill panel attachments (if equipped)
33
5.6 VentingAllLNGtanksmustventatsomepointtobeabletorefuel.LNGhasaverylowboilingpointof-130°Cto-165°C(-202°Fto-265°F)atatmosphericpressureandmustbestoredatverylowtemperatures.LNGisreferredtoasacryogenicliquid.Theboilingpointreferstoatemperatureatwhichasubstancechangesfromaliquidtoagas.Forwaterthisisabout100°C(212°F)atatmosphericpressure.LNGisconstantlychangingtoavaporastemperatureandpressureincreaseinsidethetank.
Eachtankisequippedwithapressuregaugewhichreadsthisvaporpressure.The LNG tank gauge does not indicate liquid level, only vapor pressure.Eachtankisalsoequippedwithapressurereliefvalve(seeSection 4.3.1—Automatic Relief Valves)whichrelievesat1,600kPa(230psi).Themaximumpressureforfuelingdependsoneachstation,butgenerallyshouldnotexceed1,200kPa(180psi).Followingaregeneralventingguidelines.
5.6.1 Venting to Station
Thepreferredventingmethodistousethevent-to-stationvalve.ThisvalveusestheLNGstationfilllineoradedicatedstationventlinetoreturntheexcessvaporbacktothestation.Thevent-to-stationvalveonlyworksiftheLNGfuelinghoseisattached;orifusingtheremotefillpanel,ifthededicatedventlineisattached.Youcannotfuelwhileventing.ThismethodworksonlyifthestationpressureislessthantheLNGtankpressure.Thefollowingstepsareguidelinesonly;youmustreceivepropertrainingforyourspecificstation.
1. CompleteSection 5.4—Pre-Fueling.
2. Completesteps1through8ofSection 5.5—LNG Fueling.
3a. Iftruckisequippedwitharemotefillpanel,attachdedicatedstationventlinetotheventreceptacleontheremotefillpanel.
3b. Iftruckisnotequippedwitharemotefillpanel,inspectandcleanthefuelnozzleandLNGtankreceptaclewithpressurizedair.ConnectthefuelnozzletotheLNGtank.
4. Openthevent-to-stationvalve(see Figure 18–Tank shroud labels).Youshouldhearthevaporventingthroughthefillhose/dedicatedventlineandseethehosebegintofrost.Donottouchfrostyhoseswithbarehands.
5. Monitorthetankpressureandwaituntilitdropstothedesiredlevel(LNGtankshouldequalizewiththeLNGstation).
34
5.6.1 Venting to Station (continued)
6. Closethevent-to-stationvalve.
7. Iftruckisequippedwitharemotefillpanel,disconnectdedicatedventlineandreturnittothestation.
8. ContinuewithStep10ofSection 5.5—LNG Fueling.
WARNING! Naturalgasvaporisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.WestportrecommendsnotsmokingwhileoperatingaWestportLNGSystemtruck.
WARNING! Vent-to-station valve must be closed before fueling.
5.6.2 Venting to Atmosphere
Ventingtoatmosphereshouldonlybeperformedoutsideandonlywhenventingtostationisnotpossible.Ventingtoatmospherereleasesmethanewhichisharmfultotheenvironmentandpromotesfuelloss.UsethismethodifthestationpressureexceedstheLNGtankpressure.Thefollowingstepsareonlyaguideline,youmustreceivepropertrainingforyourspecificstation.
1. CompleteSection 5.4—Pre-Fueling.
2. CompleteSteps1though8ofSection 5.5— LNG Fueling.
3. Openthevent-to-atmospherevalve(see Figure 18–Tank shroud labels).Youshouldhearthevaporventingthroughtheventstackbehindthecab.
4. Monitorthetankpressureandwaituntilitdropstothedesiredlevel.
5. Closethevent-to-atmospherevalve.
6. ContinuewithStep10ofSection 5.5—LNG Fueling.
WARNING! Naturalgasvaporisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.WestportrecommendsnotsmokingwhileoperatingaWestportLNGSystemtruck.
WARNING! Vent-to-atmosphere valve
must be closed before fueling.
35
VENTTO
ATM
VENTTO
STN
LIQUIDDRAIN
EMERGENCY SHUT-OFF VALVEClose ¼ turn tostop fuel flowto engine.
VENT TO STATIONNormally closed. Open to vent vapour through fill or vent connection.
VENT TO ATMOSPHERE
Normally closed. Open to vent vapour through
vehicle vent stack.
LIQUID DRAINService valve ONLY. Do
not operate without proper instruction /
service training.
Figure 18a—Tank shroud label (manual shut-off valve equipped) Figure 18b—Tank shroud label (automatic shut-off valve equipped)
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5.7 MinimizingVentingandFuelLossMinimizingventingandfuellossisanimportantpartofoperatingyourWestportLNGSystemtruck.Withsomebasicguidelines,youcanreducefuellossandimprovethefuelingprocess.ContactyourlocalWestportServicerepresentativeifyouhavequestions(seeAppendix C—Contact Information).
Somegeneralsuggestionstominimizeventinginclude:
• Fuelingrightbeforeashift,ratherthanthenightbefore.ThisminimizesthepressurebuildupfromLNGboil-offandkeepstheLNGcolderforlongerperiodsoftime.
• Ifventingmustoccur,useventingbacktostationratherthantoatmosphere.Ventingbacktostationwillre-collapsesomeofthevaporinsidethestation.Ventingtoatmospherereleaseslargeamountsofmethanegas,whichisharmfultotheenvironmentandpromotesfuelloss.
• UseyourWestportLNGSystemtruckasmuchaspossible.Runninglongertripswithfrequentrefuelingeventscanhelpmanagevaporinsidethetankandminimizeventingandfuelloss.
WARNING!LNG is a cryogenic (extremely cold) fluid. Avoid
contactwithliquidandplumbing.Freezingburnsandlacerationscouldoccur.WearappropriatePPEwhen
workingaroundtheLNGtankorplumbing.
WARNING! YOU MUST PARK OUTSIDE
Neverallowthetrucktoventorleakinanenclosedspace.Thegaswillriseandcollectinareaswherethere
may be an ignition source. An explosion could result.
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6. Westport LNG System Maintenance and CareWARNING!
The Westport LNG System contains high-pressure gas, liquid, and cryogenic fluids—even when the truck is turned
off. No unauthorized or untrained person should EVER attempt maintenance or repairs on a Westport LNG System truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or cryogenic burn injuries could occur.
6.1 Maintenance SchedulesThefollowingmaintenancetasksarerequiredtoensurethewarrantedperformanceoftheWestportLNGsystem.
ThesemaintenancetasksandschedulesareONLYfortheWestportLNGSystemanddonotreplacethemaintenancetasksrequiredbytheoriginalequipmentmanufacturer(OEM).PleaseseeOEMdocumentationforadditionalmaintenanceitemssuchasdaily/refuelingchecks,coolantflushes,hydraulicfluidchangeintervals,etc.
Exceptfordaily/refuelingchecks,allotherperiodicmaintenancemustbeperformedbyqualifiedWestportLNGSystemtechniciansonly.DetailedworkinstructionsforallchecksandservicingareavailablethroughWestportServiceEngineering(seeAppendix C—Contact Information).Thesepagescanbeduplicated.
CAUTION!The use of fluids other than those approved by
Westport Service for use in the Westport LNG System may void the system warranty.
Daily or Upon RefuelingCheck operator’s report
Engine check
Drain all diesel fuel-water separators engine bay
Check all engine drive belts
Drain vent stack filter, if so equipped
Fluid check Check engine oil, engine coolant & hydraulic fluid levels
Check vehicle for diesel, hydraulic & coolant leaks
Check hydraulic oil cooler for debris and/or damage
Westport LNG System
check
Check Westport LNG System for loose or damaged components
Check Westport LNG System for gas or diesel leak(s)
Check Westport LNG System for excessive frost
Check gas detection monitor—alarms and lights
Check LNG fuel level, tank pressure & tank valve positions
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Every 4 months
Conduct gas detection system function test
Every 12 months, 1,000 hours,
or 50,000 km (31,250 miles), whichever comes first
Conduct detailed gas leak check
Conduct detailed diesel leak check
Replace primary (low pressure) diesel filter
Inspect high-pressure gas accumulator
Conduct LNG tank visual inspection
Drain vent stack filter, if so equipped
Every 4,000 hours
or 200,000 km (125,000 miles), whichever comes first
Inspect all fluid hoses for leaks and deterioration
Replace hydraulic spin-on filter, if equipped
Replace high-pressure natural gas filter
Replace high-pressure (secondary) diesel filter
Replace diesel pump drive belt
Replace dosing pump filter, if equipped
Replace vent stack filter, if equipped
6.1 Maintenance Schedules (continued)
ThemaintenanceschedulescontainedonthesepagesaresubjecttochangebyWestport.
ContactWestportService(seeAppendix C—Contact Information)todetermineifthereisauniquemaintenancescheduleforyourapplication.
39
Every 4,000 hours
or 200,000 km (125,000 miles), whichever comes first
Replace LNG pump (single tank system)
Every 8,000 hours
or 400,000 km (250,000 miles), whichever comes first
Replace LNG pump (dual tank system)
Replace gas regulator (DLSR)
Replace high-pressure diesel pump
Replace diesel drain solenoid and diesel PRV
Every 5 years, 10,000 hours,
800,000 km (500,000 miles), whichever comes first
Replace natural gas pressure relief devices
Additional Recommended MaintenanceWestportrecommendsthemaintenancedescribedpreviouslydescribedbeperformedbeyondthewarrantyperiodandthroughoutthevehicle’slifetoensurepropersystemoperation.Inaddition,Westportrecommendsthefollowingmaintenancetominimizeunplanneddowntime.
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6.1.1 Natural Gas Code Required Maintenance
The owner is responsibleforensuringtheirvehicleremainscompliantwithcodesregardingtheuseofnaturalgasinvehicles.
ToensurethatyourWestportLNGSystemtruckremainscompliantwithregulatorycodesoutlinedforNaturalGasVehicles,thefollowingtwochecksneedtobedone.
1. Thegasdetectionsystemneedstobefunctionallytested.SeeWestport Work Instruction INS-10011605 Gas Detection System Function Test.
2. Thehigh-pressureaccumulatormustbeinspectedbyqualifiedpersonnel.SeeWestport Work Instruction INS-10009895 Accumulator and Pressure Relief Device Detailed Visual Inspection.
ThesecheckshavebeenincludedintheWestportLNGSystemMaintenanceSchedule.PleaseseethelistedWestportWorkInstructions(availableontheWestportServiceWebsiteathttp://service.westport.com)fordetailsontheseinspectionsandtests.IfyouhaveanyquestionsregardingcodecomplianceofyourvehiclecontactWestportService(seeAppendixC—ContactInformation).
6.1.2 Oil Drain Intervals
• FollowoildrainintervalSevereDutyifyourvehicleoperatesundereitherconditionlistedunderSevereDuty.
• FollowoildrainintervalNormalDutyifyourvehicleoperatesundereitherconditionlistedunderNormalDutyanddoesnotmeetanyconditionsunderSevereDuty.
• FollowoildrainintervalLightDutyifyourvehicleoperatesunderbothconditionslistedunderLightDutyanddoesnotmeetanyconditionsunderSevereDutyorunderNormalDuty.
Table 6—Oil drain intervals
Oil Classification
Severe Duty Normal Duty Light Duty
< 2.3 km/l (5.5 mpg) or 36,287 kg (80,000 lb)
GVW
2.3–2.8 km/l (5.5–6.5 mpg) or 36,287 kg (80,000 lb)
GVW
2.9 km/l (6.7 mpg) or < 31,751 kg (70,000 lb)
GVW
CES 20081(1)(2) 24,000 km (15,000 mi)
40,000 km (25,000 mi)
56,000 km (35,000 mi)
CES 20078(1)(2) 32,000 km (20,000 mi)
48,000 km (30,000 mi)
64,000 km (40,000 mi)
(1) The use of Centinel™ or any type of oil blending is prohibited. The use of a high-quality filter is mandatory. Refer to OEM documentation for filter part numbers.
(2) Engines equipped with an integrated Cummins Particulate Filter MUST operate on ultra-low sulfur diesel (15 ppm sulfur) fuel.
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6.2 Recommended Fluids and Capacities6.2.1 LNG Composition Specifications
TheWestportLNGSystemiscertifiedforoperationwithCaliforniaAirResourceBoard(CARB)specificationnaturalgas.Theprimaryrequirementsonnaturalgascompositionareasbelow:
• C1—Methane(minimum): 90%
• C2—Ethane(maximum): 4%
• C3andhigherhydrocarbons(maximum): 2%
• C6andhigherhydrocarbons(maximum): 0%
• Oxygen(maximum): 0%
• inerts—CO2plusN2(maximum): 4%
WestportrecognizesthatLNGcompositionwillvarydependingonthesourceandsupplymethod.Ifyourfueldoesnotmeettheabovespecification,contactWestporttodiscuss.
6.2.2 LNG Cleanliness Specifications
LNGdeliveredtotheLNGtankshouldbefilteredto5micronsnominal,10micronsabsolute.LNGtankfuelingreceptaclesmustbedriedwithcompressedairpriortofuelingtoavoidfreezingandcontaminationofthesystem.
6.2.3 Lubricating Oil Specifications
WestportrecommendsfollowingstandardCumminsoiltypes,usuallytheuseofahigh-quality15W-40multiviscosityheavy-dutyengineoilthatmeetstherequirementsofCumminsEngineeringSpecificationCES20081/CJ-4orCES20078/CI-4.Special“break-in”enginelubricatingoilsarenotrecommendedforWestportLNGSystemengines.
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6.2.4 Coolant Specifications
Westportrecommendsusingeithera50/50mixtureofgoodqualitywaterandfullyformulatedantifreeze,ora50/50premixedcoolant.Thefullyformulatedantifreezeorpremixedcoolantusedmustmeetbaseenginecoolantspecifications.Seebaseenginedocumentationforcoolanttestingand/orchangeintervals.TheapproximateextracapacityrequiredbytheWestportLNGSystemoverthebaseengineisapproximately:
• 3.37L(0.89U.S.gallons)forasingletanksystem,
• 5.52L(1.46U.S.gallons)foradualtanksystem,and
• 7.05L(1.87U.S.gallons)foratripletanksystem.
WARNING! Do not remove the pressure cap from a hot engine. Waituntilcoolanttemperatureisbelow50ºC(120°F)before removing the pressure cap. Heated coolant
spray or steam can cause personal injury.
CAUTION!Damage to the Westport LNG System can occur if
coolant mixture is incorrect. Ensure coolant mixture contains approved antifreeze.
6.2.5 LNG Pump / Steering Fluid Specifications
Inmanyapplications,Westportusesthepower-steeringassistreservoirandcircuittoprovidehydraulicfluidtothesystem’sLNGpump(s).WestportrequiresthatATF Dexron IIIoilisusedastheworkingfluidfortheLNGpump.Thehydrauliccircuitfluidcapacityisapproximately:
• 14L(3.7U.S.gallons)forasingletanksystem,
• 16L(4.2U.S.gallons)foradualtanksystem,and
• 22L(5.7U.S.gallons)forathreetanksystem
inadditiontothebaseenginefluidcapacity.
6.2.6 Diesel Fuel Specification
TheWestportLNGSystemusesnaturalgasastheprimaryfuelalongwithdieselasanignitionsourceor“liquidsparkplug”.Theamountofdieselinjectedintothecylindervaries,withagreaterpercentageusedatidle.
TrucksmaybeequippedwithanintegratedCumminsParticulateFilter.IfthetruckhasanintegratedCumminsParticulateFilter,ultra-lowsulfurdieselfuelmustbeused.SulfurcontentofthedieselfuelcanNOTexceed15ppm.
TheWestportpositionontheuseofbiodieselisdescribedinthefollowingsection.
WARNING!Seriousenginedamageandwarrantynon-compliance
can result by the use of incorrect diesel fuel.
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WARNING!Fuelmustbekeptfreeofdirtandwater.Dirtandwater
can cause severe damage to the fuel system.
CAUTION!Do not use diesel fuel blended with lubricating oil in
engines equipped with an integrated Cummins Particulate Filter.
6.2.7 Biodiesel Fuel Use in the LNG System
WestportdoesNOTrecommendorendorsetheuseofbiodieselfuelintheWestportLNGSystem.
Currentlytherearenofirmindustrystandardsonthecontentandpropertiesofbiodieselfuels.Whiledieselisonlyusedinasmallportionofthecombustionprocess,thecombustioncharacteristicsofthedieselfuelarecriticalforwarrantedengineperformance.WestportcertifiesitsengineusingtheprescribedEPACertificationFuels.Westportdoesnotcertifyenginesonanyotherfuel.
CARBcurrentlydoesnotcertifyanybiodieselfuelsforuseinCalifornia.Emissionwarrantiesarevoidedwiththeuseofnoncompliantfuels.
WARNING!Failures or damage to the Westport LNG System
(including the Westport GX engine and LNG storage and delivery system) caused by fuels not certified for use in theWestportLNGSystemareNOTwarrantablefailuresandwillNOTbecoveredundertheWestportWarranties.
6.2.8 UsableLNGTankSizes
ThefollowingtableoutlinestheusableLNGvolumethatcanbeexpectedfromthevarioussizesoftheLNGtanks.AllWestportLNGtankshaveadataplateaffixedtothetankthatclearlystatesthetankwaterequivalentvolume.TheusablevolumeofthetankissmallerthantheproductiontanksizeduetoasafetyullagespaceandthemaximumsuctionleveloftheLNGpump.
Table 7—LNG tank volumes
Production Tank Size Approximate Usable Volumes265 L (70 U.S. gallons) 208 L (55 U.S. gallons)
380 L (100 U.S. gallons) 288 L (76 U.S. gallons)
455 L (120 U.S. gallons) 356 L (94 U.S. gallons)
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6.3 Fuel WeatheringWhenevertheLNGfueltankisventedtotheatmosphere,thelightgasesarereleased(methaneandnitrogen)andtheheavygases(ethaneandpropane)areleftbehind.Whenthisoccursrepeatedly,theconcentrationofheavygasesincreases.ThisiscalledLNGweathering.Althoughweatheringcancausechangesinthespecificationofthefuelinthetank,ithaslittleeffectontheWestportLNGSystem,asliquidfuelisdrawnfromthebottomoftheLNGtank.Asaresult,LNGfuelweatheringisnotaconcerntothetruckoperator.
6.4 Running on Diesel (ROD) OperationWestportLNGSystemequippedtruckshavetheabilitytostartandrunondieselinlimpmode.Thisprovidesaconvenientwaytostarttheenginewhenthereisnohigh-pressuregasonboard(forexample,afterservice)whilesystempressureisre-establishedwiththeLNGpump.TheRODmodemayormaynotbesufficienttogetthetruckofftheroadinanemergencysituation.
Themodeisautomaticandrequiresnointeractionfromtheoperator.There is a significant power deficit,withonlyabout10%poweravailable.Neverusethismodetodrivethetruckoverroadsorhighways,ortopullaload.Continuousoperationondieselcandamagetheoxidationcatalyst.
IfyourtruckgoesintoRODoperationduringnormaldrivingyoushould:
1. Findasafespotandpullofftheroad;
2. IdletruckforafewminutesuntiltheRODmessageclears;and
3. Reporttoshopaftertripcompletion.
IfyoucannotbringyourtruckoutofRODmode,youmaybeoutoffuelortheremaybeaproblemwithyoursystem.ShutoffthetruckandcontactWestportService(seeAppendix C—Contact Information)oryourlocalshopforassistance.
AfteranextendedRODevent(5min.orlonger)itisgoodpracticetochecktheventstackfilter(seeFigure 6).Ifthereisdieselinthefilter,drainanddisposeofthedieselfuelinaccordancewithlocalrulesandregulations.
6.5 MinimizingTankContaminationTheWestportLNGSystemandfuelingstationisalwayspressurizedsoitisdifficulttocontaminatethefuel.Onecontaminationpossibilitycomesfrommoistureordirtonthefillingnozzle.Itisimportanttocleanthenozzlewithpressurizedairbetweeneachfueling.
45
7. Diagnostics and TroubleshootingYourWestportLNGSystemtruckisequippedwiththeWestportLNGSystemMonitor,whichprovidesinformationaboutthestatusoftheLNGSystem.IfafaultoccurswiththeWestportLNGSystem,anon-screenoperatormessageisdisplayed.Formoreinformationaboutthemessages,refertoSection 3.2—Westport LNG System Monitor.
YourtruckisequippedwithLNGSystemfaultcodes,whichcanberetrievedfromtheon-boardcomputerbyatrainedtechnician.ThiscapabilityallowsamoreaccurateandtimelyrepairtimeofyourWestportLNGSystemtruck.AfulllistoftroubleshootingcodesandserviceproceduresisavailableforqualifiedWestportLNGSystemtechnicians.
7.1 FrozenValvesBecauseLNGisextremelycold,mostofthetankplumbinggetsverycoldduringfueling.Theamountoffrostdependsonmoisturecontentintheairaswellastheamountofdewonthetankplumbing.Thefrostingcansometimescausehandoperatedvalvestobecomedifficulttoturnorfreezeinoneposition.Thiscanbeaninconveniencebutitdoesnotnecessarilyindicateafaultyvalve.Beforereportingafrozenvalvetoashop,tryto:
• Letthevalvethawnaturallyinambienttemperatureair;
• Dryoffvalveswithcompressedair(availableatanyLNGstation)priortofueling;or
• Ifavailable,usewater(hotorcold)andpourdirectlyontothevalvebody.
Never:
• Heatvalveswithanyopenflameorheatgun;
• Hitvalveswithobjectssuchasahammer;
• Forcevalvesopenorclosed—theymaybreak;or
• Usepliersorothertoolsonhandvalves.
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7.2 LeakatTankFuelReceptacleLeaksatthetankfuelreceptacleusuallyoccurifthesealonthestationreceptaclehasbeendamagedoriscoveredwithice.Onewaytopreventiceordebrisbuild-upistodryofftheinsideofthefuelingreceptacle(onboththetruckandtheLNGstation)usingcompressedair.Alwaysinspectthetrucknozzleaswellasthestationreceptaclebeforeuse,andreportanydamageortamperingtotheshop.
7.3 Excessive “Please Wait…” Message TimeIfyouarestartingacoldenginewherethecoolanthasnotsufficientlywarmed,youwillseethe“PleaseWait…”messagedisplayedonthedriver’sdisplay.Thisusuallyindicatesthatthecoolanttemperatureisnothighenoughtowarmthehigh-pressuregasatthepumpandassuch,theLNGpumpistypicallydisabled(Xthroughthegaspumpicon)becauseitistoocoldtooperate(“snowflake”belowgaspumpicon).
Thismessageisalsodisplayedifthehigh-pressureaccumulatorisnotfullycharged.Youcanmovethetruckaslongasyoudonotexceed10km/h(6mph)(withoutload).Analarmwillsoundifthespeedlimitisexceeded.Youcanspeeduptheenginewarm-uptimebyusingthecruisecontroltosettheengineonhighidle.Alwayscheckyourcoolantlevelduringyourpre-andpost-tripinspectionstoensureproperWestportLNGSystemoperation.
7.4 Crank,ButNoStartConditionIfyouexperienceaconditioninwhichyoucranktheenginebutitfailstofireafterashorttime(about5seconds),itcanlikelyberesetwiththefollowingprocedure:
1. Turnignitiontothe[OFF]positionandtakeoutthekey.
2. WaituntiltheWestportLNGSystemMonitorpowersdown.This wait time is very important.Evenaftercompletekey-off,thereisstillpowerstoredintheon-boardcomputerwhichdissipatesafteraboutaminute.
3. Insertkeyandturnignitionto[START];theengineshouldfirewithin5seconds.
Ifyoufollowthisprocedureandthetruckisstillnotstarting,contactyourWestportServicerepresentative(seeAppendix C—Contact Information)orshop—theremightbeanotherproblem.Ifthisproblempersists,advisetheshop.
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7.5 DifficultyFuelingwithLNGMostfuelingdifficultiesarisefromtheLNGtankpressurebeingtoohighorfromthestationfuelingequipment,suchashosesandreceptaclebeingtoowarm.Section 5.2—LNG Fueling Basicsoutlinesthegeneralguidelinesforeasyandsuccessfulfuelingprocedures.Remember:Youmusthaveproperfuelingtrainingonthespecificstationyouareusing.
7.6 JumpStartingyourLNGTruckIfyouneedtojumpstartyourLNGtrucktheon-boardgasdetectorwillbedisabledandunabletodetectanaturalgasleak.
Remembernaturalgasvaporiscolorless,hasnosmell,canaccumulateunderhoods/awningsandcanbeignitedbysparkorstaticdischarge.
Notifyyourshoptoreceivefurtherinstructions.
7.7 SweatyLNGTank/LowFuelEfficiencyTheWestportLNGSystemusesLNGastheprimaryfuelsource,whichmustbekeptatcryogenictemperatures.Tokeepthefuelcold,LNGtanksareinsulatedwithavacuumlayer.
Ifyouconsistentlynoticeexcessivecondensationor“sweat”onyourLNGtanks,yourtankvacuummayhavedegraded.
ApoorLNGtankvacuumcanalsobedetectedbyalossoffuelefficiencyand/ortheLNGtankpressurebuildsfasterthannormal.
Itisimportanttorecordtankpressures,andnoteLNGtankconditionaspartofyourpreandposttripinspections.Thesecheckshelpyoutounderstandwhatisnormalforyourvehicle.
ContactWestportService(seeAppendix C—Contact Information)ifyoususpectapoorLNGtankvacuum.
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49
8. LNG Properties and HandlingTheprimaryfueloftheWestportLNGSystemisLNG.Asacryogenicliquidwithflammablevapor,ithassomeparticularcharacteristicsandsafetyhazards.
8.1 Physical PropertiesLNGisaclearliquidthatislessdensethanwater.Itwillcauseseverefrostburnsifallowedtocontactskin.Itdoesnotsmellandboilsbetween-130°Cand-165°C(-202°Fand-265°F).Naturalgaswillriseanddisperseinaironceithasvaporized.Whenmixedwithairinconcentrationof5–15%,naturalgasisflammableandcanbeignitedbystaticdischarge.
8.2 SafetyHazards
WARNING! LNG is a cryogenic (extremely cold) fluid. Avoid
contactwithliquidandplumbing.Freezingburnsandlacerationscouldoccur.WearappropriatePPEwhen
workingaroundtheLNGtankorplumbing
WARNING! Natural gas is lighter than air and can accumulate in enclosedspaces,suchasunderthehoodorunderawnings.Ifthereisanignitionsourceanexplosioncouldresult.Neverallowthetrucktoventinan
enclosed space. PARKING OUTSIDE IS MANDATORY.
WARNING! Naturalgasiscolorlessandodorless.Youmustcheck
the operation of the gas detection monitor and listen for soundsofaleak.Ifyoudetectsignsofaleak,seeredoryellowlights,hearagasalarm,orcannotseethegreenpowerlightonthedetector,doNOTenteroroperatethe
truck.Notifytheshopfromoutsidethetruck.
WARNING! Do not stay in a natural gas vapor cloud. Natural gas
displaces oxygen and can cause asphyxiation.
WARNING! Naturalgasisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.Westportrecommendsnotsmokingwhileoperatinga
WestportLNGSystemtruck.
WARNING! Contain liquid spills as best as possible to prevent the liquidorgasfromenteringthesewage/stormdrainsystem.Keeptheresultingvaporcloudawayfrom
buildings or ventilation systems.
50
8.3 First AidIfLNGcausesburnsontheskin:
• Removeanyclothingthatmayrestrictcirculationtothefrozenarea.Donotrubfrozenparts,astissuedamagemayresult.Obtainmedicalassistanceassoonaspossible.
• Whenpractical,placetheaffectedpartofthebodyinaslightlywarmbath.Thawingmayrequire15to60minutesandshouldbecontinueduntilthepaleblueoftheskinturnspink.
• Iffrozentissuehasthawedbeforemedicalattentionhasbeenadministered,covertheareawithdrysteriledressingandalarge,bulkyprotectivecovering.
8.4 Sample LNG MSDS
MATERIAL SAFETY DATA SHEET LIQUEFIED NATURAL GAS (MSDS #582)
Revision Date: April 7, 2008Supersedes Date: February 20, 2004
Section 1 – PRODUCT AND COMPANY IDENTIFICATION
Terasen Gas Inc. Company Phone: (604) 592-7629 16705 Fraser Highway Emergency Phone: (604) 946-4818 Surrey, BC V3S 2X7 Canada
Product Name: Liquefied Natural Gas
Material Use: Various
Manufacturer: Terasen Gas LNG Plant Supplier: Terasen Gas LNG Plant 7651 Hopcott Rd 7651 Hopcott Rd Delta, BC V4G 1B7 Delta, BC V4G 1B7 Canada Canada
WHMIS Class: A – Compressed Gas; B1 – Flammable and Combustible Material – Division 1 Flammable Gases
UN/PIN Number: 1972
TDG Classification: Class 2.1 Flammable Gases
Chemical Family: Hydrocarbon Liquid
Chemical Formula: CH4 (Methane)
Molecular Weight: 16.04 (Methane)
CAS Number: 74-82-8
Trade Names and Synonyms: Liquefied Methane
51
Section 2 – HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
Appearance/Odor: Odorless, colorless liquid. This product is not odorized.
Flammable: Very flammable after vaporization to gaseous phase.
Potential Health Effects: See Section 11 for more information
Potential Environmental Effects: See Section 12 for more information.
Likely Routes of Exposure: Eye and skin contact, acute inhalation
Acute - Eye, Skin and Inhalation: Liquid or cold gas contact with skin or eyes could cause freezing or severe cryogenic burns. After vaporisation, contact with burning gas may cause burns.
Chronic- Inhalation: None
Ingestion: None
Skin Adsorption: None
Section 3 – FIRST AID MEASURES
Skin Contact: Cryogenic burns. Remove constricting clothing. Do not thaw too rapidly. Transport to hospital immediately.
Eye Contact: Get medical attention immediately.
Inhalation: Move to fresh air. Give artificial respiration if breathing has stopped. Call a physician.
Ingestion: Unlikely route of exposure as this is a gas at normal room temperature and pressure.
General Advice: Use extreme care in handling due to high flammability and risk of cryogenic burns.
Section 4 – COMPOSITION / INFORMATION ON INGREDIENTS
Component CAS Number % by Wt. Exposure Limits(1)
Methane 74-82-8 95 Simple Asphyxiant Ethane 74-84-0 3 Simple Asphyxiant Propane 74-98-6 1 Simple Asphyxiant Nitrogen 7727-37-9 1 Simple Asphyxiant
(1) See Section 8 for additional exposure limit information for C1 to C4 Aliphatic Hydrocarbon Gases.
Section 5 – FIRE FIGHTING MEASURES
Flammability: Flammable gas
Suitable Extinguishing Media: Dry Chemical (Purple-K). To suppress or contain, use water fog or high expansion foam.
Unsuitable Extinguishing Media: Do not direct water spray directly at LNG pool; this will only increase rate of vaporization. Cold vapor is heavier than air and will not readily disperse until warmed up. High expansion foam may be used to help control the vaporization rate.
Products of Combustion: Carbon dioxide and carbon monoxide
Protection of Firefighters: Very flammable after vaporization to gaseous phase. Firefighters should wear self-contained breathing apparatus (SCBA) in case of oxygen deficient atmosphere. Use Combustible Gas Indicator to determine the extent of vapor cloud.
Sensitivity to Static Discharge: Ignitable by static discharge
Sensitivity to Mechanical Impact: None
Explosive Power: Not known
52
Section 6 – ACCIDENTAL RELEASE MEASURES
Personal Precautions: Use personal protection recommended in Section 8.
Environmental Precautions: Not applicable
Methods for Containment: Evacuate area for 2000 foot (600 m) radius. Stay out of vapor cloud.
Methods for Clean-Up: Wear all protective equipment recommended in Section 8. Eliminate source of ignition.
Other Information: Allow to vaporize and disperse to atmosphere.
In case of an emergency and no response at LNG plant, call SERVICE CENTER: 1 (800) 663-9911.
Section 7 – HANDLING AND STORAGE
Handling: To be handled by trained personnel only, using equipment specifically designed for LNG, and following approved operating procedures.
Storage: Store only in vessels designed for LNG storage, and follow approved operating procedures.
Section 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION
Exposure Limits: Simple asphyxiant - Maintain 19.5% oxygen level (below 19.5% oxygen is considered to be oxygen deficient).
Constituent ACGIH (8-hour) TWA WorkSafeBC (8-hour TWA) Methane 1000 ppm 1000 ppm Ethane 1000 ppm 1000 ppm Propane 1000 ppm 1000 ppm Nitrogen None listed None listed
Personal Protection Equipment: Ensure use of proper PPE at all times when handling this product.
Eye/face: Face shield with other eye protection (safety glasses)
Skin: Insulated gloves, safety work boots, Nomex coveralls.
Respiratory: Supplied air respiratory protection to be used (airline or self- contained breathing apparatus) in cases of oxygen deficient atmospheres.
Other Considerations: Use extreme care in handling due to high flammability and risk of cryogenic burns.
Engineering Controls: Provide electrical ground for all parts of handling system. Provide adequate ventilation to maintain more than 19.5% oxygen, less than 1% methane (20% of the lower explosive limit). Use of CGI is mandatory since product is odorless.
Section 9 – PHYSICAL AND CHEMICAL PROPERTIES
Color: ColorlessOdor: OdorlessOdor Threshold (ppm): Not availablePhysical State: LiquidpH: Not applicableFreezing Point (˚C): -182.5Boiling Point (˚C): -161.5Flash Point (˚C): -187.8Evaporation Rate: RapidFlammability (solid, gas): Flammable gasLower Explosion Limit: 5% (by volume, gas phase)Upper Explosion Limit: 15% (by volume, gas phase)Vapor Pressure: Container ratingVapor Density: > 1 @ -112 ˚C (air = 1)Specific Gravity: 0.45 (water = 1)Solubility in Water (20 ˚C): 24.4 parts per millions (wt)Partition Coefficient: Octanol/water – 1.09 LogKOWAuto Ignition Temperature: 537 ˚C (gas phase)Percent Volatile (by volume): 99%Density (g/ml): 0.45 @ Boiling Point
8.4 Sample LNG MSDS (continued)
53
Section 10 – STABILITY AND REACTIVITY
Chemical Stability: YesCompatible Materials: Air, oxidizers, halidesHazardous Decomposition Products: None knownReactivity (and under what conditions): None known
Section 11 – TOXICOLOGICAL INFORMATION
LD50: Not availableLC50: Not availableAcute Effects: Liquid or cold gas contact with skin or eyes could cause freezing or severe cryogenic burns. After vaporization, contact with burning gas may cause burns.Chronic Effects: Not availableCarcinogenicity: Not considered carcinogenic by IARC, NTP, ACGIH or OSHA.Reproductive Effects: Not availableTeratogenicity: Not availableMutagenicity: Not availableIrritant: Not availableSensitizer: Not availableSynergistic Effects: Not available
Section 12 – ECOLOGICAL INFORMATION
Ecotoxicity: Not applicablePersistence / Degradability: Not applicableBioaccumulation / Accumulation: Not applicable
Section 13 – DISPOSAL CONSIDERATIONS
Disposal: Allow to vaporize and disperse to the atmosphere.
Section 14 – TRANSPORTATION INFORMATION
TDG Classification: 2.1 Flammable GasesUN/PIN Number: 1972Shipping Name: Methane, Refrigerated Liquid, or Natural Gas, Refrigerated Liquid with high methane contentSpecial Shipping Information: Transport only in shipping container designed for LNG and follow approved operating procedures.
Section 15 – REGULATORY INFORMATION
DSL (Canada): This product is on the DSL list.WHMIS Class: A – Compressed Gas; B1 – Flammable and Combustible Material – Division 1 Flammable Gases
Section 16 – OTHER INFORMATION
National Fire Protection Association (NFPA 704) Ratings:
Health 2 LEGEND 0 = minimal hazard Flammability 4 1 = slight hazard Instability 0 2 = moderate hazard (For methane from NFPA 325) 3 = severe hazard 4 = extreme hazard
Prepared by: AMEC Earth & Environmental Phone Number: (604) 294-3811 Occupational Hygiene Preparation Date: April 7, 2008 and Safety Group
Additional Information and Comments: This MSDS has been updated from a 9 section MSDS (2004-02-20) to a 16 section MSDS on 2008-03-10. All sections and the order that which they appear have been changed as per American National Standard – For Hazardous Industrial Chemicals – Material Safety Data Sheets Preparation (ANSI Z400.1-2004).
New text has been added in Section 8: Exposure Guidelines, WorkSafeBC and ACGIH exposure limits for methane, ethane, and propane (WorkSafeBC Occupational Health and Safety Regulation (OHSR), Guidelines Part 5, Table of Exposure Limits for Chemical and Biological Substances and ACGIH TLVs and BEI’s, Threshold Limit Values for Chemical Substances and Physical Agents & Biological Exposure Indices, 2007, respectively).
The information contained in this document applies to this specific material as supplied. It may not be valid for this material if it is used in combination with any other materials. It is the user’s responsibility to satisfy oneself as to the suitability and completeness of this information for their own particular use.
Information Sources: Various
54
Appendix A. Daily Log SheetThisappendixcontainsasampledailylogsheetthatyoucanduplicate.
55
Da
ily L
og
Sh
ee
tNa
me:
Date
:
Truc
k/Tr
acto
r No.
:
Odom
eter
Rea
ding
:
Pre-
trip
insp
ectio
n of
Wes
tpor
t LNG
Sys
tem
Befo
re e
nter
ing
the
cab:
Ch
eck
gas
dete
ctio
n m
onito
r is
pow
ered
Ch
eck
gas
dete
ctio
n m
onito
r is
NOT
in a
larm
Afte
r ent
erin
g th
e ca
b:
Chec
k ga
s de
tect
ion
mon
itor o
pera
tion
by p
ushi
ng [T
EST]
but
ton
Ch
eck
dies
el a
nd L
NG fu
el le
vels
Insi
de th
e en
gine
com
partm
ent:
Chec
k fo
r lea
ks, d
amag
e or
tam
perin
g
Chec
k ho
ses
and
fittin
gs
Drai
n al
l die
sel f
uel-w
ater
sep
arat
ors
Dr
ain
vent
sta
ck fi
lter
In
spec
t hig
h-pr
essu
re d
iese
l pum
p an
d be
lt
Insp
ect h
ydra
ulic
pum
p
Insp
ect F
CM
Chec
k en
gine
oil
leve
ls
Chec
k en
gine
coo
lant
leve
ls
Chec
k hy
drau
lic le
vels
Outs
ide
the
engi
ne c
ompa
rtmen
t:
Ch
eck
gas
filte
r loc
ated
on
fram
e ra
il fo
r lea
ks o
r dam
age
Ch
eck
LNG
Syst
em (t
anks
, val
ves,
plu
mbi
ng) f
or fr
ost o
r his
sing
Ch
eck
for p
rese
nce
of s
econ
dary
relie
f val
ve c
ap
Chec
k ve
nt-t
o-st
atio
n va
lve
is c
lose
d
Chec
k th
e ve
nt s
tack
is n
ot v
entin
g ex
cess
ivel
y
Chec
k hy
drau
lic o
il co
oler
is u
nblo
cked
and
free
of d
ebris
Reco
rd s
yste
m p
ress
ure:
Ta
nk 1
[T
ank
2]
[Tan
k 3]
Fuel
ing
Chec
k LN
G fu
elin
g:
Quan
tity
of L
NG a
dded
Odom
eter
read
ing
at fi
ll
Ta
nk 1
leve
l afte
r fill
[Tan
k 2
leve
l afte
r fill]
[Tan
k 3
leve
l afte
r fill]
Chec
k Ve
nt-t
o-St
atio
n Va
lve
is c
lose
d
Dies
el fu
elin
g:
Quan
tity
of d
iese
l add
ed
Od
omet
er re
adin
g at
fill
Post
-trip
insp
ectio
n of
the
Wes
tpor
t LNG
Sys
tem
Chec
k LN
G sy
stem
:
No
gas
leak
s (n
o fro
st, h
issi
ng s
ound
, or a
larm
)
No h
ydra
ulic
or c
oola
nt le
aks
No
leak
s in
eng
ine
com
partm
ent
Reco
rd s
yste
m p
ress
ure:
Ta
nk 1
[T
ank
2]
[Tan
k 3]
Note
s:
56
Da
ily L
og
Sh
ee
tNam
e:
Date:
Truck/Tractor No.:
Odometer Reading:
Pre-trip inspection of Westport LNG System
Before entering the cab:
Check gas detection m
onitor is powered
Check gas detection m
onitor is NOT in alarm
After entering the cab:
Check gas detection m
onitor operation by pushing [TEST] button
Check diesel and LNG fuel levels
Inside the engine compartm
ent:
Check for leaks, dam
age or tampering
Check hoses and fittings
Drain all diesel fuel-w
ater separators
Drain vent stack filter
Inspect high-pressure diesel pump and belt
Inspect hydraulic pum
p
Inspect FCM
Check engine oil levels
Check engine coolant levels
Check hydraulic levels
Outside the engine compartm
ent:
Check gas filter located on fram
e rail for leaks or damage
Check LNG System
(tanks, valves, plumbing) for frost or hissing
Check for presence of secondary relief valve cap
Check vent-to-station valve is closed
Check the vent stack is not venting excessively
Check hydraulic oil cooler is unblocked and free of debris
Record system pressure:
Tank 1
[Tank 2]
[Tank 3]
FuelingCheck LNG fueling:
Quantity of LNG added
Odometer reading at fill
Tank 1 level after fill
[Tank 2 level after fill]
[Tank 3 level after fill]
Check Vent-to-Station Valve is closed
Diesel fueling:
Quantity of diesel added
Odom
eter reading at fill
Post-trip inspection of the Westport LNG System
Check LNG system:
No gas leaks (no frost, hissing sound, or alarm)
No hydraulic or coolant leaks
No leaks in engine com
partment
Record system pressure:
Tank 1
[Tank 2]
[Tank 3]
Notes:
57
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58
Appendix B. Towing and RecoveryIngeneral,non-accidentrelatedtowingandrecoveryoperationsonWestportLNGSystemequippedtrucksareidenticaltoconventionaldieseltrucks.Thefollowingadditionalprecautionsandlimitationsapply:
1. Ensurethatthegasdetectionmonitorisnotindicatingyelloworredbeforecommencingtowing/recovery.
2. AbsolutelyDONOTSMOKEinoraroundtheWestportLNGSystemtruckduringrecoveryoperations.Naturalgasvaporishighlyflammable.
3. Donottouchanytruckhosesorlinesthatappearfrosty.LNGpipingisverycoldandcancausesevereburnsorfrostbitewhenincontactwithskin.
4. Bealertforvaporcloudsnearthegroundorpoolsofliquidform,indicatingaLNGleak.CeaserecoveryimmediatelyandcontactWestportServicepersonnel.
5. OnlyrecoverimmobilizedtrucktoapprovedWestportLNGSystemrepairfacilities.DonotattemptmaintenanceontheWestportLNGSystem.
6. ImmobilizedWestportLNGSystemtruckMUSTNOTbedroppedoff/storedindoorsattherepairshopovernight.Notifyrepairshoppersonnelofthedrop,andthatLNGispresentonthetruck.
WARNING! YOU MUST PARK OUTSIDE
Neverallowthetrucktoventorleakinanenclosedspace.Thegaswillriseandcollectinareaswherethere
may be an ignition source. An explosion could result.
WARNING! The Westport LNG System contains high-pressure
gas, liquid, and cryogenic fluids—even when the truck is turned off. No unauthorized or untrained person should EVER attempt maintenance or repairs on a
Westport LNG System truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or
cryogenic burn injuries could occur.
59
Appendix C. Contact InformationToreportanemergency,maintenanceissue,providefeedback,oraskageneralortechnicalquestion:
Contact Westport Service at:
North America
1-888-WPT-HPDI [email protected]
Australia
Head Office 101–1750West75thAvenue
Vancouver,B.C.CanadaV6P6G2
phone:1-604-718-2000fax:1-604-718-2001
http://www.westport-hd.comhttp://service.westport.com
WestportGXandLNGSystemOperator’sManualP/N:10014256
Revision:0Date:February2009