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LNG vehicles Regulation

1. Figure 4 5 LNG identification mark 46 2 Other European regulations and standards under develooment Engine emissions regulations for LNG HDVs Work is currently in progress for a new UNECE regulation that will include retrofitted LNG HDVs which is expected to be included in UNECE R115 and new Euro V LNG HDVs which are not yet covered by emissions regulations Gas quality composition standards Biomethane and LNG used as a vehicle fuel The European Commission has mandated CEN to prepare standards for biomethane for use in transport amp injection in natural gas pipelines M 475 This mandate includes the requirement for a European Standard for a quality specification for biomethane to be used as a fuel for vehicle Draft new Regulation on uniform provisions concerning the approval of specific LPG liquefied petroleum gases or NG compressed and liquefied natural gas bio methane dual fuel retrofit systems and dual fuel retrofitted engines to be installed in heavy duty applications work carried by the UNECE DF Task Force LNG eS CORRIDORS oF LNG BC D4 1 Vehicle Regulations State of the Art Public engines A specific Technical Committee called CEN TC 408 has been established to execute this mandate Its work is currently in progress LNG fuel composition has been added to the scope of CEN TC 408 46 3 International regulations and standards under development ISO DIS 12617 gt Liquefied natural gas veh
2. LNG CORRIDORS 9 on LNG BC D4 1 Vehicle Regulations State of the Art Public standards and have enormous potential to reach future Euro VI emission standards without complex exhaust gas aftertreatment technologies thereby avoiding increased procurement and maintenance costs To accomplish its objective the LNG Blue Corridors project has defined a roadmap of LNG refuelling points along four corridors covering the Atlantic area green line the Mediterranean region red line and connecting Europe s South with the North blue line and its West and East yellow line accordingly In order to implement a sustainable transport network for Europe the project has set the goal to build 14 new LNG or L CNG stations both permanent and mobile at critical locations along the Blue Corridors while building up a fleet of approximately 100 LNG Powered Heavy Duty Vehicles HDVs These vehicles will be provided by the primary manufacturers of LNG powered HDVs including Volvo Iveco Daimler Hardstaff and Renault Trucks This European project is financed by the Seventh Framework Programme FP7 with the amount of 7 96 M total investments amounting to 14 33 M involving 27 partners from 11 countries LNG Blue Corridors Project is supported by the European Commission under the Seventh Framework Programme FP7 The sole responsibility for the content of the website lies with the authors It does not necessarily reflect the opin
3. fuel leakage limit value and testing method for LNG vehicles Engine standards Technical specifications for LNG engines and diesel LNG dual fuel engines are in the work plan CNGV standards need to be adapted Other standards are the same as for CNGVs Filling receptacle for vehicle standards currently the same as LPGV cylinder standard GB T 18363 2001 CNG filling receptacle standard is being revised to include LNGV tanks Fuel quality standards LNG Characteristics standard Refuelling infrastructure standards o GBT 20368 2006 gt Production storage and handling of Liquefied Natural Gas LNG o NB T 1001 2011 gt Technical standard for vehicle liquefied natural gas fuelling station Environmental standards requirement is to be in compliance with the existing standards Special device standards o QC T 755 2006 gt Technology requirements of special equipment for LNG vehicle includes LNG tank with liquid level display pressure gauge and other accessories Vaporizer and Fuel refuelling system o GB T 20734 2006 gt Mounting requirements for LNG vehicle special equipment gas storage system and vaporizer primarily o Standards for LNGV piping safety valve shut off valve cylinder valve vaporizer mixer filling receptacle need to be created LNG a
4. Fuel rail LNG E B L LNG BC D4 1 Vehicle Regulations State of the Art Public Means the pipe or duct that connects the fuel injection devices LNG nozzle Means device which permits quick connection and disconnection of fuel supply hose to the LNG receptacle in a safe manner LNG filling receptacle Means device connected to a vehicle or storage system which receives the LNG fuelling nozzle and permits safe transfer of fuel The receptacle consists as minimum of a receptacle body and of a check valve mounted inside the body 13 LNG BC D4 1 Vehicle Regulations State of the Art Public 3 Abbreviations E degrees Celsius CNG Compressed Natural Gas ECU Electronic Computer Unit HDV Heavy Duty Vehicles LCNG Compressed Natural Gas sourced from LNG LNG Liquefied Natural Gas OEM Original Equipment Manufacturer 14 LNG BC D4 1 Vehicle Regulations State of the Art Public 4 LNG vehicles regulations amp standards 41 General tramework in Europe The document s aim is to give an overview regarding the regulations and standards implicated in each country and affecting the construction and homologation of heavy duty vehicles powered by liquefied natural gas As such the main aspects covered in this analysis are linked with safety though some minor environmental issues are also referenced In first place it is to be noted that experience with LNG heavy duty vehicles has come after years of e
5. IDIADA 1 Cryogenic tank 120 C at 11 bar Heat exchanger LNG in some cases it is inside the tank Pressure regulator Output at 5 8 bar NG injectors High pressure tank CNG at 200 bar Pressure regulator Input at 200 bar Output at 5 8 bar NG injectors ECU os ee w As described above only a few elements within the fuel system are different for LNG compared to CNG vehicles The state i e pressure and temperature in the injectors is the same The main difference is the natural gas state at output of the tank Once the natural gas leaves the cryogenic tank it goes to the pressure regulator across a heat exchanger in the case of LNG system That exchanger increases its temperature Exclusively those specific devices from LNG system will be analysed in this document The rest of elements meet international CNG regulation in this respect ECE regulation 110 Based on the information mentioned in the last point the following countries have been considered LNG gt CORRIDORS or LNG BC D4 1 Vehicle Regulations State of the Art Public arranged by number of vehicles sold 441 Spain Fuel tank Must meet the requirements outlined in standard UNE EN 1251 2001 Cryogenic vessels Transportable vacuum insulated vessels of not more than 1000 litres volume In some cases if the security of the system is proved special instructions based on this standard or NFPA 57 Liquefied Natural Gas LNG Vehic
6. In these applications engine performance and autonomy are good with present technologies which are well adapted to this cleaner alternative fuel However when analyzing the consumption data the equivalence in autonomy of 1 litre of diesel oil is 5 litres of CNG compressed to 200 bar Five times more volume of fuel prevents the use of CNG in heavy road transport because its volume and weight would be too great for a long distance truck This opens the way for LNG Liquefied Natural Gas which is already the medium used to transport natural gas by ship to any point of the globe NG liquefies at 162 C below zero and the cost in energy is only 5 of the original gas This liquefied state gives LNG the advantage of very high energy content Only 1 8 litres of LNG are needed to meet the equivalent autonomy to 1 litre of diesel oil A 40 ton road tractor in Europe needs a tank of 400 to 500 litres for a 1 000 km trip its equivalent volume with liquid gas would be 700 to 900 litres of LNG a tank dimension that could be easily fitted to the lateral of the truck chassis LNG is therefore opening the use of NG to medium and long distance road transport LNG has huge potential to contribute to meeting the Commission s targets for greenhouse gas reduction and air quality while simultaneously reducing dependency on crude oil and guaranteeing security of supply Natural gas powered heavy duty vehicles already comply with Euro V emission
7. check valve the pressure relief valve and the excess flow valve only for LNG applications The LNG automatic valve The materials constituting the LNG automatic valve which are in contact with the LNG when operating shall be compatible with the test LNG Operating specifications The LNG automatic valve shall be so designed as to withstand a pressure of 1 5 times the working pressure MPa without leakage or deformation The LNG automatic valve shall be so designed as to be leak proof at a pressure of 1 5 times the working pressure MPa The insulation resistance test This test is designed to check for a potential failure of the insulation between the two pin coil assembly and the LNG automatic valve casing Apply 1 000 V DC between one of the connector pins and the housing of the automatic valve for at least 2 seconds The minimum allowable resistance shall be 10 MQ The LNG check valve The materials constituting the LNG check valve which are in contact with the LNG when operating shall be compatible with the test LNG In order to verify this compatibility the procedure described in Annex 5D shall be used Operating specifications LNG E B 47 LNG BC D4 1 Vehicle Regulations State of the Art Public The LNG check valve shall be so designed as to withstand a pressure of 1 5 times the working pressure MPa without leakage and deformation at cryogenic temperature The LNG pressure relief valve The materials cons
8. Annex 4L Provisions on the approval of LNG pressure and or temperature sensor The purpose of this annex is to determine the provisions on the approval of the LNG pressure and or temperature sensor LNG pressure and temperature sensors The LNG pressure and temperature sensors are classified in Class 5 The LNG pressure and or temperature sensor test procedures The LNG pressure and or temperature sensor test procedures shall conform to the requirements of Class 5 and follow the test procedures in Annex 5 with the following specific requirements Insulation resistance test This test is designed to check for a potential failure of the insulation between the LNG pressure and or temperature sensor connection pins and the housing Apply 1 000 V DC between one of the connector pins and the housing of the LNG pressure and or LNG 45 CORRIDORS 6 if gE LNG BC D4 1 Vehicle Regulations State of the Art Public temperature sensor for at least 2 seconds The minimum allowable resistance shall be gt 10 MQ The material constituting the LNG pressure and temperature sensors which is in contact with the LNG when operating shall be compatible with the test LNG The LNG pressure and or temperature sensor shall be so designed as to operate at temperatures as specified in Annex 50 The Class 5 part of the LNG pressure and temperature sensors shall withstand a pressure up to 1 5 times the working pressure MPa at the temperatu
9. C Gas composition Hydrogen shall be limited to 2 per cent by volume when tanks are manufactured from steel with an ultimate tensile strength exceeding 950 MPa External surfaces Tanks are not designed for continuous exposure to mechanical or chemical attack e g leakage from LNG 41 CORRIDORS 6 if LNG BC D4 1 Vehicle Regulations State of the Art Public cargo that may be carried on vehicles or severe abrasion damage from road conditions and shall comply with recognized installation standards However tank external surfaces may be inadvertently exposed to a solvents acids and alkalis fertilizers and b automotive fluids including gasoline hydraulic fluids glycol and oils Leakage and venting In case LNG tanks are located in enclosed spaces for extended periods of time e g for service leakage and venting of natural gas or other flammable substances from the tank shall be dealt with properly to avoid the dangers due to releasing flammable substances in enclosed spaces Vehicle LNG tank s shall have a design hold time build without relieving minimum of 5 days after being filled net full and at the highest point in the design filling temperature pressure range e Annex 4 Provisions on the approval of flexible fuel lines or hoses for CNG and hoses for LNG The purpose of this annex is to determine the provisions on the approval of flexible hoses for use with CNG or LNG This annex covers t
10. be connected by appropriate joints for example two part compression joints in steel tubes and joints with olives tapered on both sides The number of joints shall be limited to a minimum Any joints shall be made in locations where access Is possible for inspection In a passenger compartment or enclosed luggage compartment the fuel lines shall be no longer than reasonably required and in any case shall be protected by a gas tight housing They shall not apply to vehicles of categories M2 or M3 where the fuel lines and connections are fitted with a sleeve that is resistant against CNG and that has an open connection to the atmosphere Automatic valve LNG E B 38 LNG BC D4 1 Vehicle Regulations State of the Art Public An automatic valve shall be installed as close as practicable after the vaporizer in the LNG system Filling unit or receptacle The filling unit shall be secured against rotation and shall be protected against dirt and water When the LNG container or tank is installed in the passenger compartment or an enclosed luggage compartment the filling unit shall be located at the outside of the vehicle or in engine compartment Fuel selection system and electrical installation The electrical components of the LNG system shall be protected against overloads Vehicles with more than one fuel system shall have a fuel selection system to ensure that no more than one fuel at the same time is supplied to the eng
11. emission and powertrain according to the R115 mentioned regulations Abstract R110 IS015500 PED R115 and the technical knowledge by the test departments involved 444 United Kingdom No special requirements are required in the United Kingdom for the different components 26 LNG BC D4 1 Vehicle Regulations State of the Art Public Fuel tank Must meet the requirements outlined in Regulation R110 In dual vehicles the diesel tank must fulfil R34 4 5 Summary of regulations in force 45 1 International standards ISO 12991 2012 Liquefied natural gas LNG Tanks for on board storage as a fuel for automotive vehicles Status international standard published Abstract ISO 12991 2012 specifies the construction requirements for refillable fuel tanks for liquefied natural gas LNG used in vehicles as well as the testing methods required to ensure that a reasonable level of protection from loss of life and property resulting from fire and explosion is provided It is applicable to fuel tanks intended to be permanently attached to land vehicles but can be used as a guide for other modes of transport Other related standards ISO 13984 ISO 21029 1 ISO 21011 ISO 21013 1 ISO 13985 ISO 15500 and ISO 15501 series from 15500 1 to 15500 20 and 15501 1 to 15501 2 Road vehicles Compressed natural gas CNG fuel system components and fuel systems Status international standard published but some parts currently in rev
12. excess flow limiting device Means a device that automatically shuts off or limits the gas or liquid flow when the flow exceeds a set design value Manual valve Means a manual valve rigidly fixed to the cylinder or tank Pressure relief valve discharge valve Means a device that prevents a predetermined upstream pressure being exceeded Service valve Means an isolation valve that is closed only when servicing the vehicle Filter Means a protective screen that removes foreign debris from the gas or liquid stream Fitting Means a connector used in a piping tubing or hose system LNG fuel pump Means a device to establish the supply of LNG to the engine by increasing the pressure of the fluid LNG 10 LNG BC D4 1 Vehicle Regulations State of the Art Public liquid or vapour Rigid fuel lines Means tubing that has not been designed to flex in normal operation and through which natural gas flows Gas supply device Means a device for introducing gaseous fuel into the engine intake manifold carburettor or Injector Gas air mixer Means a device for mixing the gaseous fuel and intake air for the engine Gas injector Means a device for introducing gaseous fuel into the engine or associated intake system Gas flow adjuster Means a gas flow restricting device installed downstream of a pressure regulator controlling gas flow to the engine Pressure regulator Means a device used to control
13. of compressed natural gas as a fuel for automotive vehicles o GB 17926 2009 gt CNG cylinder valves Compressed natural gas cylinder valve for vehicle o GB 19533 2004 gt Periodic inspection of steel CNG cylinders Periodic inspection and evaluation of steel gas cylinders for the on board storage of compressed natural gas as a fuel o GB 24160 2009 gt Composite CNG cylinders Hoop wrapped composite cylinders with steel liner for the on board storage of compressed natural gas as a fuel for automotive vehicles o GB 24162 2009 gt Periodic inspection of composite CNG cylinders Periodic inspection and evaluation of hoop wrapped fibre reinforced composite gas cylinders with metal liners of compressed natural gas for automotive vehicles Refuelling stations standards o JB T 10298 2001 2009 gt Compressors The natural gas compressor for the vehicle gas station Most of the LNGV standards refer to the CNGV standards A lot of work on LNGV standards is currently ongoing or in the work plan Basic standards same as CNGV standards LNG already covered by GB T 17676 1999 GB T 17895 1999 needs to be updated Vehicle standards o QC T 754 2006 gt Specifications for LNG vehicle tests o GB 18442 2001 gt Cryo insulation pressure vessels o CNGV standards need to be adapted to include technical requirements of retrofit test LNG 63 LNG BC D4 1 Vehicle Regulations State of the Art Public
14. the pressure of CNG or LNG Filling unit or receptacle Means a device fitted in the vehicle used to fill the container or tank in the filling station Electronic control unit LNG Means a device that controls the gas demand of the engine and other engine parameters and cuts off automatically the automatic valve required by safety reason Heat exchanger Vaporizer LNG 11 LNG BC D4 1 Vehicle Regulations State of the Art Public Means a device used to change the state of LNG into CNG Liquefied Natural Gas LNG Also called Liquid Natural Gas means a cryogenic liquid produced by reducing the temperature of natural gas to about 161 7 C at atmospheric pressure and stored for use as a vehicle fuel Compressed Natural Gas CNG Means natural gas that has been compressed and stored for use as a vehicle fuel Boil off Means gas created by evaporation of LNG due to ambient heat input Venting Means the discharge of vapours out of the storage container tank Venting system Means a system that controls the release of natural gas from the LNG storage system LNG trapping Means the containment of LNG in an enclosure of constant volume Cryogenic temperature Means temperatures below 40 C Inner vessel or inner tank Means part of the fuel tank that contains LNG Outer vessel or outer jacket Means part of the fuel tank that encases the inner vessel or inner tank s and its insulation system
15. typically dealt between the Regulation 110 and the filling station equipment LNG o BL E 15 CORRIDOR S LNG BC D4 1 Vehicle Regulations State of the Art Public requirements for nozzles specially This aspect was years ago solved for CNG vehicles by the establishment of two standardised sets of nozzles and receptacles NGV1 typical for light duty CNG vehicles designed and manufactured according to ISO 14469 20 MPa filling unit receptacle for M and N vehicles 0 ae O oosa gt at lt R 15 SRI Al SoC D R1 25 1 Pe ome 7 8 0 2 mi O 0 05 212 0 Ole Tosa 13 6 20 05 Ole 0 05 A p 17 0 1 9 20 5 20 1 al Figure 4 1 Receptacle for M1 and N1 vehicles 5 Or O Q D D Qu D an 16 LNG BC D4 1 Vehicle Regulations State of the Art Public NGV2 typical for heavy duty CNG vehicles designed and manufactures according to ISO 14469 20 MPa Filling unit Size 2 receptacle for M2 Mx N and N vehicles Dimensions in millimetres 0 35 0 1 29 0 1 Y Ln rt wT a ai REP 47 Ss oo x i 5 gt m 0 05 O 0 05 A 32 0 1 Figure 4 2 Receptacle tor M2 M3 N and N3 vehicles There are several approaches concerning the design and operation of LNG filling units This has made it impossible for the LNG Task Force to establish a given standardised size of the LNG nozzle receptacle This challenge is evidenced by the unfinish
16. 1251 1 EN1251 3 EN1252 1 EN1418 EN1435 EN1626 EN1708 1 EN1797 1 EN10045 1 EN10204 EN12213 EN12 http www unece org fileadmin DAM trans main wp29 wp29regs R049r5e pdf and http www unece org fileadmin DAM trans main wp29 wp29reqs R049r5am2e pdf e http www unece org fileadmin DAM trans main wp29 wp29regs 2013 R049r6e pdf and http www unece ora fileadmin DAM trans main wp29 wp29regs 2013 R049r6am1le pdf LNG BLUE 30 LNG BC D4 1 Vehicle Regulations State of the Art Public UK DOT 4L HSE 1999 gt Welded insulated cylinders This standard provides a complete set of specifications for welded insulated cylinders 1999 36 EC gt Transportable Pressure Equipment Directive The purpose of this Directive is to enhance safety with regard to transportable pressure equipment of dangerous goods by road 46 Summary regulation ongoing 461 ECE R110 As mentioned above ECE R110 has been updated in order to include the requirements for LNG components The proposal has been prepared as a new consolidated version Revision 3 of UN Regulation No 110 A summary is explained following PART I APPROVAL OF SPECIFIC COMPONENTS OF MOTOR VEHICLES USING LIQUEFIED NATURAL GAS LNG IN THEIR PROPULSION SYSTEM e Markings The sample of specific component or multifunctional components submitted for approval shall bear the trade name or mark of the manufacturer and the type including one concerning designation on
17. 4 18 464 Some aspects uncovered in the current regulations LNG nozzles and receptacles There is no European or International standard that ensures the compatibility of LNG nozzles and receptacles There is ongoing work for the standardisation of a given LNG receptacle dimension upcoming ISO Standard ISO DIS 12617 which will then be incorporated in the UNECE R110 regulation but this work does not cover the compatibility between nozzles and receptacles There are three main types of nozzles and receptacles JC Carter Parker Kodiak and Macrotech LNG LNG BC D4 1 Vehicle Regulations State of the Art Public Types of Nozzles Types of Receptacles e SS Parker Kodiak J 8 n e5 Parker Kodiak Macrotech Li O ___ lt EA lt A lt A A w Macrotech Figure 4 6 Main types of nozzles and receptacles Source JC Carter Parker Kodiac and Macrotech JC Carter JC Carter There are compatibility issues in two cases Between Parker Kodiak nozzles and JC Carter receptacles and Between Parker Kodiak nozzles and JC Carter receptacles On one hand a Parker Kodiak nozzle requires a Parker Kodiak receptacle because it relies on Parker s unique twist clamping whereas a JC Carter or a Macrotech nozzle can fill any receptacle On the other hand any nozzle can fill the Parker receptacle whereas JC Carter and Macrotech receptacles can only be filled by JC Carter or Macrotech nozzles JC Carter nozzles and Macrotech receptacle
18. EUROPEAN COMMISSION DG MOVE SEVENTH FRAMEWORK PROGRAMME GC SS12012 7 3 GA No 321592 Dissemination O Written By Javier LEBRATO NGVA Nad ge LECLERCQ MSW ony 28 11 2013 Jes s Gallego IDIADA and WP2 participants ara I er re eran E am ET EA N E 2 pe LNG BC D4 1 Vehicle Regulations State of the Art Public Colla o re r o O POSE UE RI 4 1 1 What is the LNG BLUE CORRIDORS Pro elas nisan aiana a ainaani 4 1 2 Current status of Regulations affecting the construction and operation of LNG vehicles 6 2 Teme and denm 2 ee en aa rar eee wise ene E AE EE E EEEE TAA E wn 7 s ADIE MANO Semitic 14 4 LNG vehicles regulations amp Standards cssssssssssssssssssessssecscsessesssessesssessessesssecssseseesssesesssesseeeseeseacsseseeesaes 15 4 1 General framework in EO isis 15 4 2 General framework in the U S on ccssessesssssssssssssessssssssssesscsssessessesessessssncsucsessesssssssessessesecsesseeseeeceseaseneees 18 4 3 Current European L NGV Markets and Main Actors cccsesssssecsssessessssssesesssessessseessssssesssesseeseesee 19 4 4 Summary of national requirements for different European countri8S o cocconinnoncononnonncnonnonocnons 21 A gt 4 een ee E ne ee ee On N ee eT eee Ne N EE 23 A O y PPP PO E A Re RP OO SGU OU E EE 24 AA The Neme nad Sacos once taa 25 Re NANG WRN GONE hee ccce cnn phcce ce ctese te EEEE E i a decease eee 26 4 5 Summary of regulations TORO uns as 27 A51 Intemational S
19. Filter ISO 15500 18 2012 Fittings ISO 15500 19 2012 Part 20 Rigid fuel line in material other than stainless steel ISO 15500 20 2007 and ISO WD 15500 LNG 28 LNG BC D4 1 Vehicle Regulations State of the Art Public 20 ISO 15501 Road vehicles Compressed natural gas CNG fuel systems Part 1 Safety requirements ISO 15501 1 2012 Part 2 Test methods ISO 15501 2 2001 ISO 21014 2006 gt Cryogenic vessels Cryogenic insulation performance Stage international standard published Abstract defines practical methods for determining the heat leak performance of cryogenic vessels The methods include measurement on both open and closed systems It neither specifies the requirement levels for insulation performance nor when the defined methods should be applied These requirements may be defined in design or operational standards regulations ISO 21009 2006 2008 gt Cryogenic vessels Static vacuum insulated vessels Stage international standard published It specifies requirements for the design fabrication inspection and testing of static vacuum insulated cryogenic vessels designed for a maximum allowable pressure of more than 0 5 bar Specifies operational requirements for static vacuum insulated vessels designed for a maximum allowable pressure of more than 0 5 bar 50 kPa It may also be used as a guideline for vessels designed for a maximum allowable pressure of less than 0 5 bar 50 kPa LNG 29 L
20. NG BC D4 1 Vehicle Regulations State of the Art Public 45 2 European standards A Engine emissions regulations for LNG HDVs UNECE R49 regulates engine emissions for heavy duty vehicles The emissions from positive ignition PI engines fuelled with natural gas were included in UNECE R49 rev 5 which latest amendments entered into force on July 26 2012 Heavy duty dual fuel vehicles and engines have now been included in the UNECE R 49 rev 6 regulation for the first time This revision of the R 49 regulation first entered into force on January 27 2013 and an amendment was introduced on July 15 2013 All new Euro VI LNG HDVs are therefore now covered by the R 49 regulation EN1251 2 2000 gt Cryogenic vessels Transportable vacuum insulated vessels of not more than 1000 litres volume Design fabrication inspection and testing Status European Standard published 15 05 00 Content e Part 1 fundamental requirements e Part2 design fabrication inspection and testing e Part 3 operational requirements Description Cryogenic equipment Cryogenics Pressure vessels Transportable Vacuum insulation Volume Design Inspection Approval testing Non destructive testing Radiographic testing Surfaces Defects Stress analysis Elastic deformation Welding Flammable material Cross references BS 5500 1997 CODAP 1995 EN287 1 EN287 2 EN288 3 EN288 4 EN288 8 EN473 EN729 2 EN729 3 EN895 EN910 EN962 EN970 EN
21. ast partially applicable to LNGVs since both vehicle types are partially similar and using the same components at least after the vaporizer 26 CNGV standards are currently in place 16 CNGV standards including 10 national standards and 6 industry standards have been released by the automotive industry and 10 have been released by other industries CNGV standards released by the automotive industry Basic standards o GB T 17676 1999 gt Identification marks Natural gas vehicle and liquefied petroleum gas vehicle Identification marks o GB T 17895 1999 gt Terms Natural gas vehicle and liquefied petroleum gas vehicle Vocabulary Vehicle standards o GB T 26780 2011 gt Collision safety requirements The safety requirement of fuel system for compressed natural gas vehicle in the collision o GB T 23335 2009 gt Approval program Natural gas vehicles Engineering approval LNG 61 LNG BC D4 1 Vehicle Regulations State of the Art Public evaluation program o GB T 29125 2012 gt Fuel consumption test Test methods for fuel consumption of CNG vehicles Engine standards o QC T 691 2011 gt Mono fuel vehicles Cars with natural gas single fuel engine technology conditions o QC T 692 2011 gt Dual fuel vehicles Gasoline natural gas dual fuel engine technology conditions o GB 17691 2005 gt Gas fuelled positive ignition engine emissions requirements Limits and measu
22. ations State of the Art Public LNG system Means an assembly of components tanks valves flexible fuel lines etc and connecting parts fuel lines fittings etc fitted on motor vehicles using LNG in their propulsion system and related components up to and including the vaporizer Other parts downstream from the vaporizer shall be considered as CNG components Tank or vessel Means any storage system used for liquefied natural gas Type of tank Means tanks that do not differ in respect of the dimensional and material characteristics Accessories fitted to the container or tank Means the following components but not limited to them either separate or combined when fitted to the container or tank Manual valve Means valve which is operated manually Pressure sensor indicator Means a pressurized device which indicates the gas or liquid pressure Excess flow valve Means valve which automatically shuts off or limits the gas flow when the flow exceeds a set design value Gas tight housing Means a device that vents gas leakage to outside the vehicle including the gas ventilation hose LNG BC D4 1 Vehicle Regulations State of the Art Public Valve Means a device by which the flow of a fluid may be controlled Automatic valve Means a valve that is not operated manually Non return valve or check valve Means an automatic valve that allows gas fluid to flow in only one direction Excess flow valve
23. duly accredited representative This application will be submitted beside the documentation required in this case Annex 1B This annex is shown in details in the original ECE R110 document e Approval An approval number shall be assigned to each type of vehicle approved Its first two digits shall indicate the series of amendments incorporating the most recent major technical amendments made to the Regulation at the time of issue of the approval If the vehicle submitted for approval pursuant to this Regulation is provided with all the necessary specific components for the use of liquefied natural gas LNG in its propulsion system meets the requirements of explained below approval of that vehicle type shall be granted These requirements LNG 33 LNG BC D4 1 Vehicle Regulations State of the Art Public are General The LNG system of the vehicle shall function in a good and safe manner at the working pressure and operating temperatures for which it has been designed and approved All components of the system shall be type approved as individual parts or multifunctional parts pursuant to Part I mentioned above Notwithstanding the provisions mentioned no separate type approval of the LNG electronic control unit is required if the LNG electronic control unit is integrated into the engine electronic control unit and is covered with a vehicle installation type approval according to Part II of this document and to Regulatio
24. ecides the items from gas supply to refuelling station for standards and allocates relevant institutes or organizations to work out the standards In terms of the NGV standards China Automotive Technology and Research Centre CATARC had worked out a full set LNG 60 CORRIDORS 6 if LNG BC D4 1 Vehicle Regulations State of the Art Public of NGV standards including CNG and LNG vehicles fuelling stations gas system etc Up to now nearly 400 types of gas vehicle including chassis produced by 60 enterprises are listed on national new product announcements of motor vehicles covering bus car truck and municipal special vehicles in which 254 types are related to dual fuel vehicles In the last few years the Chinese government and some of the industrial supervision departments have sped up pace to make legal and technical standards for NGVs More than 50 national standards and industry standards have been implemented divided in the following 8 sections basic standard vehicle engine special device gas cylinder for vehicle fuel quality filling machine and filling stations However a lot of national standards or technical specifications still need to be amended and enforced including specification for safety testing cylinder testing daily maintenance for gas supply system etc The NGV standards system includes two parts CNGV standards system and LNGV standards system Most of the CNGV standards are also at le
25. ecific component e Tank e Accessories fitted to the container e Pressure regulator e Automatic valve e Manual valve e Gas supply device e Gas flow adjuster e Rigid fuel line e Filling unit or receptacle e Non return valve or check valve Pressure relief valve discharge valve primary and secondary Filter LNG CORRIDORS 9 on LNG BC D4 1 Vehicle Regulations State of the Art Public e Pressure or temperature sensor indicator e Excess flow valve e Service valve e Electronic control unit e Gas tight housing e Fitting e Ventilation hose e Fuel rail e Heat exchanger vaporizer e Natural gas detector e Fuel pump for LNG Multi functional component Means any of the above mentioned specific components combined or fitted together as a component Approval of a vehicle Means the approval of a vehicle type of categories M and N with regard to its LNG system as original equipment for the use in its propulsion system Vehicle type Means vehicles fitted with specific components for the use of LNG in their propulsion systems which do not differ with respect to the following conditions the manufacturer the type designation established by the manufacturer the essential aspects of design and construction e Chassis floor pan obvious and fundamental differences e The installation of the LNG equipment obvious and fundamental differences LNG BC D4 1 Vehicle Regul
26. ed standardisation work being carried out at international level by the ISO Technical Committee 22 Road Vehicles Sub Committee 25 Vehicles Using Gaseous Fuels which has been working for the last years on the preparation of ISO DIS LNG ot BI UE 17 A CORRIDORS LNG BC D4 1 Vehicle Regulations State of the Art Public 12617 LNG Connector for Refuelling Vehicles This standard is already approved and will come into force in July 2014 when Contracting Parties will also conform their national regulations to the new R 110 Regulation incorporating the design specifications mating dimensions geometry and tolerances material requirements etc for LNG nozzles and receptacles to be submitted for certification Between many other requirements it states that both components have to be Designed to minimize the possibility of an incorrect assembly Designed to be secure against displacement distortion warping or other damage Constructed to maintain operational integrity Designed to prevent spillage in excess of 30 cm during disconnection The initial intention of the stakeholders involved in the development of the ECE R110 was to update the requirements contained in it as soon as the ISO DIS 12617 got approved Until then depending on the L NGV manufacturer differences in design could occur creating potential compatibility Issues 42 General framework in the U S As with Europe the experience with L NGVs in the US ma
27. er and or tank shall not be less than 200 mm above the road surface This provisions shall not apply if the container and or tank is adequately protected at the front and the sides and no part of the container is located lower than this LNG 35 LNG BC D4 1 Vehicle Regulations State of the Art Public protective structure The fuel container s and or tank s shall be mounted and fixed so that the following accelerations can be absorbed without damage occurring when the container s and or tank s are full Vehicles of categories M1 and N1 a 20g in the direction of travel b 8g horizontally perpendicular to the direction of travel Vehicles of categories M2 and N2 a 10g in the direction of travel b 5g horizontally perpendicular to the direction of travel Vehicles of categories M3 and N3 a 6 6 g in the direction of travel b 5g horizontally perpendicular to the direction of travel A calculation method can be used instead of practical testing if its equivalence can be demonstrated by the applicant for approval to the satisfaction of the Technical Service Accessories fitted to the LNG tanks Excess flow valve The excess flow valve can be fitted inside or directly on the LNG tank in a protected position Pressure relief valve primary The primary pressure relief valve outlet shall be connected to an open ended pipe away system to move vented gas away to a high level Consideration shall be given t
28. for 100 cycles between 0 and working pressure WP The LNG non return valve has to comply with the test procedures for the Class 5 component Annex 40 Provisions on the approval of the LNG fuel pump The purpose of this annex is to determine the provisions on the approval of the LNG fuel pump LNG fuel pump requirements among others include The materials constituting the LNG fuel pump which are in contact with the LNG when operating shall be compatible with the test LNG The LNG fuel pump in Class 5 shall be designed to operate at a temperature from 162 C to 85 C The device shall comply with the test procedures for the Class 5 components The LNG fuel pump shall be constructed in such a manner as to avoid LNG trapping The LNG fuel pump shall be provided with pressure control device to maintain the pressure within the operating pressure range e Annex 5 Annex 5D CNG LNG compatibility test A non metallic part in contact with CNG LNG shall not show excessive volume change or loss of weight Resistance to n pentane according to ISO 1817 with the following conditions a Medium n pentane b Temperature 23 C tolerance according to ISO 1817 c Immersion period 72 hours Requirements LNG LNG BC D4 1 Vehicle Regulations State of the Art Public Maximum change in volume 20 per cent After storage in air with a temperature of 40 C for a period of 48 hours the mass compared to the original value
29. hree types of CNG flexible hoses a b c and one type of LNG hose d a High pressure hoses Class 0 b Medium pressure hoses Class 1 c Low pressure hoses Class 2 d LNG hoses Class 5 Annex 4H Provisions on the approval of the electronic control unit The purpose of this annex is to determine the provisions on the approval of the electronic control unit Electronic control unit 42 LNG BC D4 1 Vehicle Regulations State of the Art Public It can be any device which controls the CNG LNG demand of the engine and establishes the cut off of the automatic valve in case of a broken fuel supply pipe or in case of stalling of the engine or during a crash The switching off delay of the automatic valve after stalling of the engine may not be more than 5 seconds The device may be equipped with an automatic ignition advance timing adjuster integrated in the electronic module or separated The device may be integrated with dummy injectors to permit a correct functioning of the gasoline electronic control unit during CNG LNG operation The electronic control unit shall be so designed to operate at temperatures as specified in Annex 50 Annex 41 Provisions on the approval of the LNG heat exchanger vaporizer The purpose of this annex is to determine the provisions on the approval of the LNG heat exchanger vaporizer The LNG heat exchanger vaporizer can be any device made for vaporizing the cr
30. hybrids which are primarily focused on urban applications o Some countries regions and municipalities have their own rules and exemptions for LNG vehicles and NGVs more generally but these rules and exemptions only apply in the territories themselves Maintenance facilities workshops handling LNG vehicles Parking structures receiving LNG vehicles 47 Summary of North American codes regulations and standards NFPA 52 gt Vehicular Gaseous Fuel Systems Code 2013 Applicability NFPA 52 safeguards people and installations with requirements that mitigate the fire and explosion hazards associated with compressed natural gas CNG and liquefied natural gas LNG engine fuel systems and fuelling facilities Provisions cover the design installation operation and maintenance of CNG and LNG fuel systems on all vehicle types plus their respective compression storage and dispensing systems This Code applies to all facilities with LNG storage in containers of 70 000 gallons or less Comments Very good source of guidance for CNG LNG and L CNG vehicles and fuelling facilities ALNG 56 CORRIDORS LNG BC D4 1 Vehicle Regulations State of the Art Public NFPA 57 gt Liquefied Natural Gas LNG Vehicular Fuel Systems Code 2002 Applicability NFPA 57 shall apply to the design installation operation and maintenance of liquefied natural gas LNG engine fuel systems on vehicles of all types to their associated f
31. icability Fuel system components for NGVs excludes LNG components upstream of vaporizer LNG 57 CORRIDORS oF gE LNG BC D4 1 Vehicle Regulations State of the Art Public Comments Primarily for converted vehicles 49 CFR 178 57 gt Specification 4L welded insulated cylinders Applicability LNG vehicular fuel tank requirement called out in NFPA 57 Comments Option is meeting ASME Boiler and Pressure Vessel Code 49 CFR 393 67 gt Liquid fuel tanks Applicability Tanks containing or supplying fuel for the operation of commercial motor vehicles 49 CFR 393 65 FMCSR gt All fuel systems Applicability Commercial vehicles in interstate commerce Comments DOT Federal Motor Carrier Safety Regulations May have been adopted by states for intrastate application Was not written with NGVs in mind but may be legally applicable ASME Boiler and Pressure Vessel Code Section VIII Pressure Vessels Applicability Some sections applicable to LNG containers used on vehicles and in fuelling stations State level codes California Code of Regulations CCR Title 13 Div 2 Ch 4 Article 2 Applicability Fuel systems using LNG in 13 CCR 935 CNG in 13 CCR 934 Comments California vehicle requirements California Code of Regulations CCR Title 8 Div 1 Ch 4 Subchapter 1 Applicability CNG and LNG Storage Tanks Comments California fuel storage requirements LNG 58 LNG BC D4 1 Vehicle Regulations State of the Art P
32. icles Connector for refuelling vehicles Status Under development by ISO TC 22 SC 25 Enquiry stage close of voting 2013 04 02 Target publication date 2014 04 14 ISO DIS 12614 series 12614 1 to 12614 18 gt Road vehicles Liquefied natural gas LNG fuel system components Status Under development by ISO TC 22 SC 25 Enquiry stage close of voting 2013 04 18 Part 1 General requirements and definitions ISO DIS 12614 1 Part 2 Performance and general test methods ISO DIS 12614 2 Part 3 Check valve ISO DIS 12614 3 Part 4 Manual valve ISO DIS 12614 4 Part 5 Tank pressure gauge ISO DIS 12614 5 Part 6 Overpressure regulator ISO DIS 12614 6 Part 7 Pressure relief valve ISO DIS 12614 7 Part 8 Excess flow valve ISO DIS 12614 8 Part 9 Gas tight housing and ventilation hose ISO DIS 12614 9 Part 10 Rigid fuel line in stainless steel ISO DIS 12614 10 LNG 53 LNG BC D4 1 Vehicle Regulations State of the Art Public Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Fittings ISO DIS 12614 11 Rigid fuel line in material other than stainless steel ISO DIS 12614 12 Pressure control regulator ISO DIS 12614 13 Differential pressure fuel content gauge ISO DIS 12614 14 Capacitance fuel content gauge ISO DIS 12614 15 Heat exchanger vaporizer ISO DIS 12614 16 Natural gas detector ISO DIS 12614 17 Gas temperature sensor ISO DIS 1261
33. ine for a limited duration Dual fuel vehicles using diesel as the primary fuel for igniting the air gas mixture are allowed in cases where these engines and vehicles meet mandatory emission standards The electrical connections and components in the gas tight housing shall be constructed such that no sparks are generated The LNG system shall be designed to prevent any LNG trapping The LNG system in category M vehicles shall be equipped with a natural gas detector and or gas tight housing The LNG system in category N vehicles may be equipped with a natural gas detector if the fuel storage tank and associated piping is mounted on the exterior of the vehicle without the possibility of gas trapping If the fuel storage tank is located inside the cargo area of a category N vehicle then a natural gas detector and or gas tight housing is mandatory PART III ANNEXES All those annexes referenced above keep the original reference from the ECE R110 All these annexes are summarized following e Annex 3B Liquid tanks Vacuum insulated vessels for the on board storage of natural gas as a fuel for automotive vehicles This annex sets out minimum requirements for refillable liquid tanks The tanks are intended only for LNG 39 LNG BC D4 1 Vehicle Regulations State of the Art Public the on board storage of liquid natural gas as a fuel for automotive vehicles to which the tanks are to be fixed Tanks shall be of any austenitic stai
34. ion of the European Union Neither the FP7 nor the European Commission are responsible for any SEVENTH FRAMEWORK PROGRAMME use that may be made of the information contained therein This document corresponds to the first deliverable within work package 4 It is an overview of the regulations about LNG HD It will be available in internet through the next link http www Ingbluecorridors eu which can be consulted by any user It has a public access LNG BC D4 1 Vehicle Regulations State of the Art Public 12 Current status of Regulations affecting the construction and operation of LNG vehicles Experience has shown that the lack of common standards within the European Union is the main obstacle for a wide deployment of heavy duty vehicles powered by liquefied natural gas LNG This report describes the state of the art of existing and forthcoming regulations and standards in the main European countries where LNG vehicles have already been placed in the market In countries where LNG vehicles have not been introduced yet it is usually difficult to find any legal framework directly connected to this vehicle technology In this regard a new version of Regulation No 110 regarding the type approval provisions for vehicles equipped with LNG propulsion system has been already approved and is expected that will come into force in July 2014 when Contracting Parties will also conform their national regulations to this new Regulatio
35. ision and or under development by ISO TC 22 SC 25 Note For LNG vehicles these standards apply to the components installed downstream from the vaporizer ISO 15500 Road vehicles Compressed natural gas CNG fuel system components Part 1 General requirements and definitions ISO 15500 1 2000 ISO 15500 1 2000 Amd 1 2003 and ISO WD 15500 1 LNG 27 CORRIDORS o7 gE LNG BC D4 1 Vehicle Regulations State of the Art Public Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 Part 12 Part 13 Part 14 Part 15 Part 16 Part 17 Part 18 Part 19 Performance and general test methods ISO 15500 2 2012 Check valve ISO 15500 3 2012 Manual valve ISO 15500 4 2012 Manual cylinder valve ISO 15500 5 2012 Automatic valve ISO 15500 6 2012 Gas injector ISO 15500 7 2002 and ISO WD 15500 7 Pressure indicator ISO 15500 8 2001 and ISO WD 15500 8 Pressure regulator ISO 15500 9 2012 Gas flow adjuster ISO 15500 10 2001and ISO WD 15500 10 Gas air mixer ISO 15500 11 2001 and ISO WD 15500 11 Pressure relief valve PRV ISO 15500 12 2001 and ISO WD 15500 12 Pressure relief device PRD ISO 15500 13 2012 Excess flow valve ISO 15500 14 2012 Gas tight housing and ventilation hose ISO 15500 15 2001 and ISO WD 15500 15 Rigid fuel line in stainless steel ISO 15500 16 2012 Flexible fuel line ISO 15500 17 2012
36. l Inspection minimum content harmonized in 2009 40 EC Pollution emissions regarding R49 EURO VI Noise pollution regarding 70 157 EEC or ECE R51 Abstract R110 R115 R34 R49 R51 70 157 EEC 443 The Netherlands Fuel tank Those are not specifically tested as in the past LNG tanks from the two main manufacturers there Chart Indox were exhaustively tested according to the Transportable Pressure Equipment Directive 25 LNG BC D4 1 Vehicle Regulations State of the Art Public Receptacle The connection of the tank to the vehicle is tested based on the G forces mentioned in the R110 Piping Low temperature test in case of non metallic fuel lines Valves The PRV s Pressure relief valve need to comply with the R110 or ISO15500 tests NG detector Natural gas detectors for potential natural gas leakages are checked according to R110 ECU and to evaluation by a technician Sensors ECU signals for pressure sensors and fuel gauge are checked according to R110 ECU and to evaluation by a technician Other LNG specific components The manufacturer of the Vaporizer must prove that the system does not break in case of gas leak In The Netherlands there were no other regulations or drafts available other than the R110 So R110 and the PED are the most used documents in combination with the R115 for the vehicle evaluation component safety according to R110 building instructions user manual etc according to R115
37. lowing requirements The manufacturer of the receptacle may require a specific LNG nozzle type to be used The LNG filling receptacle test procedures The LNG filling receptacle shall conform to the requirements of Class 5 and follow the test procedures with the following specific requirements The non metallic material constituting the LNG filling receptacle shall be compatible with LNG The LNG filling receptacle shall be free from leakage at a pressure of 1 5 times the working pressure MPa The filling unit shall withstand 7 000 cycles in the durability in terms of low temperature room temperature and high temperature cycling Annex 4K Provisions on the approval of the LNG pressure control regulator The purpose of this annex is to determine the provisions on the approval of the LNG pressure LNG B B 44 LNG BC D4 1 Vehicle Regulations State of the Art Public control regulator LNG pressure control regulator The material constituting the regulator which is in contact with the LNG when operating shall be compatible with the test LNG In order to verify this compatibility it shall comply with the tests for Class 5 Classification and test pressures The pressure regulator that is in contact with the pressure of the LNG is regarded as Class 5 The pressure control regulator shall be leak proof with the outlet s of that part closed off It shall be so designed to operate at temperatures as specified in Annex 50
38. may not decrease more than 5 per cent Annex 50 Operating temperatures The operating temperatures shall be Assembled on the engine 20 C 105 C 20 C 120 C 20 C 85 C Cold C 40 C 105 C 40 C 120 C 40 C 85 C LNG L 162 C 105 C 162 C 120 C 162 C 85 C Note the LNG L temperature is the temperature of the fluid inside the components for surrounding temperatures use M or C Since for LNG saturation temperature and pressure have a direct relationship as shown in the table below higher minimum temperatures shall be allowed for LNG components based on the described test pressure 9 on LNG E LNG BC D4 1 Vehicle Regulations State of the Art Public e Annex 7 Provisions on LNG identification mark for public service vehicles of categories M2 and M3 N2 and N3 The sign consists of a sticker which shall be weather resistant The colour and dimensions of the sticker shall fulfil the following requirements Colours a Background green b Border white or white reflecting c Letters white or white reflecting one 5 Or O Q D D Qu D an LNG BC D4 1 Vehicle Regulations State of the Art Public Dimensions a Border width 4 6 mm b Character height 25 mm c Character thickness 4mm d Sticker width 110 150 mm e Sticker height 80 110 mm The word LNG shall be centrered in the middle of the sticker
39. mpressed Natural Gas and Liquefied Natural Gas Vehicles To Existing Maintenance Facilities Published by the Clean Vehicle Education Foundation 2012 Applicability This document looks at the modifications necessary for existing liquid fuel maintenance facilities to service both CNG and LNG vehicles Comments The basic national codes are outlined and the rational and or assumptions used to develop the codes are discussed in this guideline Technical Guideline for the Design and Operation of Facilities Used For Indoor Repair Storage and Cargo Handling for Vehicles Fuelled by Compressed Natural Gas and Liquefied Natural Gas Published by the Canadian Natural Gas Vehicle Alliance CNGVA 2012 Applicability This document is intended to be a reference guideline related to facility design and operations issues at indoor facilities used for the repair storage or cargo handling of CNG and LNG fuelled vehicles Comments Canada does not currently have a code specifying the requirements for maintaining storing and or cargo handling of natural gas fuelled vehicles indoors In addition to these codes standards and guidelines local building codes and regulations vary by location so local officials always need to be consulted about the required NGV workshop upgrades 48 Summary of Chinese regulations and standards The National Clean Auto Leading Group is taking the lead to organize the setup of NGV regulations and standards It d
40. n 110 It is not going to be possible to homologate a LNG vehicle until this happens in countries such as France and Germany where currently there is not a national legal framework Even though this document covers vehicles of categories M and N with regard to the installation of specific components for the use of liquefied natural gas LNG in their propulsion system the European L NGV industry has shown experience mainly in the use of Medium amp Heavy Duty Commercial Vehicle applications categories N2 amp N3 and recently some in pilot projects with Medium and Heavy Duty Buses categories M2 amp M3 LNG BC D4 1 Vehicle Regulations State of the Art Public 2 Terms and definitions For a complete understanding of this document some definitions have to be taken into consideration For the sake of coherence most of those have been aligned to already existing definitions commonly used by the European NGV industry Pressure Means relative pressure versus atmospheric pressure unless otherwise stated Service pressure or Operating pressure Means the settled pressure at a uniform gas temperature of 15 C Service pressure for LNG means the intended settled pressure of the tank in use as declared by the manufacturer Operating temperatures Means maximum values of the temperature ranges at which safe and good functioning of the specific component is ensured and for which it has been designed and approved Sp
41. n No 10 it is about electromagnetic compatibility The vehicle type approval shall also be pursuant to the applicable provisions laid down in Annex 4H see annex section of this Regulation The materials used in the system shall be suitable for use with LNG as applicable All components of the system shall be fastened in a proper way The LNG system shall be pressurized at the working pressure and tested for leakage with a surface active agent without formation of bubbles for three minutes or by using a demonstrated equivalent method The LNG system shall be installed such that is has the best possible protection against damage such as damage due to moving vehicle components collision grit or due to the loading or unloading of the vehicle or the shifting of those loads No appliances shall be connected to the LNG system other than those strictly required for the proper operation of the engine of the motor vehicle With this regard vehicles may be fitted with a heating system to heat the passenger compartment and or the load area which is connected to the LNG system The heating system referred shall be permitted if in the view of the Technical Services responsible for conducting type approval the heating system is adequately protected and the required LNG 34 CORRIDORS 6 if LNG BC D4 1 Vehicle Regulations State of the Art Public operation of the normal LNG system is not affected Identification of LNG f
42. nless steel material design or method of manufacture suitable for the specified service conditions This annex is based upon a working pressure less than 26 MPa Service conditions Standard service conditions The standard service conditions specified in this section are provided as a basis for the design manufacture inspection testing and approval of tanks that are to be mounted permanently on vehicles and used to store natural gas at cryogenic temperatures for use as a fuel on vehicles Use of tanks The service conditions specified are also intended to provide information on how tanks made to this Regulation may safely be used to a manufacturers of tanks b owners of tanks c designers or contractors responsible for the installation of tanks d designers or owners of equipment used to refuel vehicle tanks e suppliers of natural gas and f regulatory authorities who have jurisdiction over tank use Periodic requalification Recommendations for periodic requalification by visual inspection or testing during the service life shall be provided by the tank manufacturer on the basis of use under service conditions specified herein Each tank shall be visually inspected at least every 120 months after the date of its entry into service on the vehicle vehicle registration and at the time of any reinstallation for external damage and deterioration including under the support straps The visual inspection shall be perf
43. o preventing any blockage or freezing of the pipe away The LNG primary relief valve shall not vent into the gas tight housing if fitted LNG 36 LNG BC D4 1 Vehicle Regulations State of the Art Public Pressure relief valve secondary The secondary relief valve may relieve gas immediately from its outlet Protection from water ingress and damage shall be considered The secondary relief valve outlet shall not be connected to the same pipe away as the primary relief valve The LNG secondary relief valve shall not vent into the Gas tight housing if fitted Manual fuel shut off valve The manual fuel shut off valve shall be mounted directly on the LNG tank in a protected position It should be readily accessible Manual vapour shut off valve The manual vapour shut off valve shall be mounted directly on the LNG tank in a protected position It should be readily accessible Vent line or connector The vent line or connector may be mounted inside or on the LNG tank in a protected position It should be readily accessible The vent connector shall be suitable for the purpose at temperatures indicated in Annex 50 see annex section for the working pressure of the LNG tank Venting management system The primary pressure relief valve shall be piped to a vent stack which extends to a high level The primary and secondary relief valve outlets shall be protected by from fouling by dirt debris snow ice and or water The vent
44. operating temperatures M or C for moderate or cold temperatures L for LNG as appropriate Every tank shall also bear a marking plate with the following data clearly legible and indelible a Serial number b Gross capacity in litres c The marking LNG d Service pressure Working pressure MPa e Mass kg f Manufacturer g Year and month of approval e g 96 01 h The marking PUMP INSIDE Pump Delivery Pressure MPa if the LNG fuel pump is C2 BNE 5 LNG BC D4 1 Vehicle Regulations State of the Art Public mounted on the tank where the is the value of the pump delivery pressure All them shall be conspicuously affixed in the space destined e Approval If the LNG components samples submitted for approval meet the following requirements approval of the type of component shall be granted These are The LNG tanks shall be type approved pursuant to the provisions laid down in Annex 3B see annex section A system shall be provided for preventing the fuel tank from being overfilled Provisions on components fitted to the LNG tank The LNG tank shall be equipped at least with the following components which may be either separate or combined Pressure relief valve manual valve and excess flow device The tank may be equipped with a gas tight housing if necessary The components pressure relief valve manual valve and excess flow device shall be type approved pursuant to the pr
45. ormed by a Technical Service designated or recognized by the Type Approval Authority in accordance with the LNG CORRIDORS 40 6 if LNG BC D4 1 Vehicle Regulations State of the Art Public manufacturer s specifications tanks without label containing mandatory information or with labels containing mandatory information that are illegible in any way shall be removed from service If the tank can be positively identified by manufacturer and serial number a replacement label may be applied allowing the tank to remain in service Tanks involved in collisions Tanks that have been involved in a vehicle collision shall be reinspected by an agency authorized by the manufacturer unless otherwise directed by the Competent Authority having jurisdiction Tanks that have not experienced any impact damage from the collision may be returned to service otherwise the tank shall be returned to the manufacturer for evaluation Tanks involved in fires Tanks that have been subject to the action of fire shall be reinspected by an agency authorized by the manufacturer or condemned and removed from service Maximum pressure The maximum allowable working pressure MAWP shall be defined by the manufacturer and correspond to the nominal primary relief valve setting The maximum allowable working pressure Shall be less than 26 MPa Temperature range Temperature of liquid in tanks may vary from a minimum of 195 C to a maximum of 65
46. ovisions laid down in Annex 4 see annex section Provisions regarding other LNG components The components shown shall be type approved pursuant to the provisions laid down in the annexes which can be determined from the table below LNG heat exchanger vaporizer 4I LNG filling receptacle 4 Pressure control regulator AK LNG Pressure and or 4L temperature sensor indicator Natural gas detector 4M N Automatic valve check valve 4 the pressure relief valve excess LNG o8 B UE 32 CORRIDORS LNG BC D4 1 Vehicle Regulations State of the Art Public flow valve manual valve and non return valve Fuel pump e Specification on LNG components The materials of the components that are in contact with LNG shall be compatible with them see Annex 5D in annex section Those parts of components whose correct and safe functioning is liable to be influenced by LNG high pressure or vibrations have to be submitted to relevant test procedures described in the annexes mentioned PART Il APPROVAL OF VEHICLES WITH REGARD TO THE INSTALLATION OF SPECIFIC COMPONENTS OF AN APPROVED TYPE FOR THE USE OF LIQUEFIED NATURAL GAS LNG IN THEIR PROPULSION SYSTEM e Application for approval The application for approval of a vehicle type with regard to the installation of specific components for the use of liquefied natural gas LNG in its propulsion system shall be submitted by the vehicle manufacturer or by his
47. r delivering CNG LNG to electronic multi point gas injection systems in heavy duty vehicle applications for OEM and aftermarket customers 20 LNG BC D4 1 Vehicle Regulations State of the Art Public Figure 4 1 shows the total population of LNG trucks sold from OEM and converted in each European country Total number of LNG trucks Figure 4 3 LNG Trucks per country including original and converted 44 Summary of national requirements for different European countries It is important to consider that an LNG on board fuel system is not so different from a CNG one The reason behind the use of liquefied natural gas instead of compressed natural gas is the higher energy density of the first one making it possible to store more energy in a given storage volume via LNG than with CNG In fact the engines installed in both CNG and LNG vehicles are finally fed by natural gas in gaseous state Once the fuel leaves the cryogenic storage tank on demand by the engine it enters the heat exchanger vaporizer and then heads to the pressure regulator where its pressure conditions are adapted to those required by the engine inlet The diagram below describes in general terms the main devices involved in both technologies LNG technology on the left side and CNG technology in the right side LNG BL DORS 2 1 LNG BC D4 1 Vehicle Regulations State of the Art Public Figure 4 4 Comparison between LNG and CNG components Source
48. re corresponding to rated service pressure from the table in Annex 50 at room temperature and at the maximum temperature from Annex 50 Annex 4M Provisions on the approval of the natural gas detector The purpose of this annex is to determine the provisions on the approval of the natural gas detector Natural gas detector The material constituting the natural gas detector which is in contact with the natural gas when operating shall be compatible with the test gas The natural gas detector test procedures It shall be so designed as to operate at temperatures as specified in Annex 50 Insulation resistance test This test is designed to check for a potential failure of the insulation between the connection pins and the housing of the natural gas detector Apply 1 000 V DC between one of the connector pins and the housing of the natural gas detector for at least 2 seconds The minimum allowable resistance shall be 10 MQ The natural gas detector shall comply with relevant electromagnetic compatibility EMC requirements according to Regulation No 10 03 series of amendments or equivalent LNG r LNG BC D4 1 Vehicle Regulations State of the Art Public Annex 4N Provisions on the approval of the automatic valve check valve pressure relief valve excess flow valve manual valve and non return valve for LNG applications The purpose of this annex is to determine the provisions on the approval of the automatic valve the
49. rement methods for exhaust pollutants from compression ignition and gas fuelled positive ignition engines of vehicles III IV V Refuelling equipment standards o GB T 19236 2003 gt Nozzles Fuelling nozzle for CNG dispenser o GB T 19237 2003 gt Dispensers Compressed natural gas dispenser for vehicle Gas cylinder for vehicle standard o GB T 18363 2001 gt Filling receptacle Filling receptacle of CNG vehicle Special device standards 6 items o Technical specifications for CNG special equipment o Installation requirements o Decompression regulator of CNG o CNGVs special devices o Electromagnetic valves o High pressure pipes CNGV standards released by other industries Vehicle standards o GB T 18437 1 2009 gt CNGV retrofits The technical criterion of refitting for vehicle by using gas Part 1 Compressed natural gas automobile o GB 19344 2003 gt Gas supply system requirements and tests Technique requirement and test method of leaking safety of gas supply system on using gas vehicle 62 LNG BC D4 1 Vehicle Regulations State of the Art Public o GB T 27876 2011 gt Maintenance requirements Technical specification for the maintenance of compressed natural gas vehicle Gas standard o GB 18047 2000 gt CNG Compressed natural gas as vehicle fuel Gas cylinder and parts standards o GB 17258 2011 gt Steel CNG cylinders Steel cylinders for the on board storage
50. rket was borne from experiences gathered with the use of CNG Nevertheless the US possesses broader experience in the use of LNG probably due to the substantial changes in the energy sector caused by the shale gas era Currently the main legal framework for CNG and LNG components systems approvals is based on the US National Fire Protection Association NFPA Code N 52 on Vehicular Gaseous Fuel Systems Code first edition in 1998 last edition in 2013 the US National Fire Protection Association NFPA Code N 57 on LNG Vehicular Fuel Systems 2002 The Society of Automotive Engineers SAE Standard J2343 on Recommended Practices for LNG Medium and Heavy Duty Powered Vehicles the Code of Federal Regulations CFR N 49 Subpart 178 57 and Subpart 393 E on Welded Insulated Cylinders and Fuel Systems respectively the Compressed Gas Association CGA Standard 1 1 2 on Cylinders for Compressed Gases and on Cargo and Portable Tanks for Compressed Gases In addition to this the ISO TC 22 SC 25 has also worked during the last years in the preparation of the LNG 18 LNG BC D4 1 Vehicle Regulations State of the Art Public ISO 12991 on LNG Tanks for on board storage as a fuel for automotive vehicles While compressed natural gas CNG vehicles have been used extensively in other countries since the late 1940s it was not until the late 1970s that their use in the United States became extensive enough to warrant preparation of a national s
51. s are compatible as well as Macrotech nozzles and JC Carter receptacles It is also important to note that adaptors between different types of nozzles and receptacles are illegal in the EU for safety reasons JC Carter nozzle is the de facto standard in North America and China There are hundreds of JC Carter nozzles in service across the world Macrotech and JC Carter receptacles which are fully compatible with JC Carter nozzles are the most common in North America and China There is a lot of experience globally with the JC Carter nozzles connecting to the Macrotech receptacle Nearly all the LNG stations built in Europe in the recent years use JC Carter nozzles and Macrotech for gas return Parker Kodiak nozzles are used in some stations almost exclusively in the UK and the LNG CORRIDORS 6 iy 55 LNG BC D4 1 Vehicle Regulations State of the Art Public Netherlands Examples of other aspects that are not covered by the current European and International regulations and standards in force or under development Fuelling infrastructure operations including safety aspects in the refuelling operation of LNG vehicles Dutch PGS 33 guidelines under development Part 1 LNG truck fuelling Weights and dimensions for LNG vehicles Current situation o Dir 96 53 EC regulates weight restrictions in the EU Member States o Derogations to Dir 96 53 EC are currently only proposed for electric battery trucks and
52. stack shall be sized to prevent flow restriction due to pressure drop Gas exiting the vent stack or secondary relieve valve shall not impinge on enclosed areas other vehicles exterior mounted systems with air intake i e air conditioning systems engine intakes or engine exhaust In the case of dual tanks the primary relief valve outlets piping for each tank may be manifold to a common stack LNG 37 LNG BC D4 1 Vehicle Regulations State of the Art Public Rigid and flexible fuel lines LNG rigid fuel lines shall be made of austenitic stainless steel or copper either seamless or welded The LNG rigid fuel line may be replaced by a flexible fuel line if used in Class 5 They shall be secured such that they shall not be subjected to vibration or stresses At the fixing point the fuel line flexible or rigid shall be fitted in such a way that there is no metal to metal contact Rigid and flexible fuel gas line shall not be located at jacking points At passages the fuel lines shall be fitted with protective material LNG fuel line shall be insulated or protected in those areas where low temperature can damage other components and or harm people Fitting or gas connections between the components Soldered joints and bite type compression joints are not permitted for CNG Bite type compression joints are not permitted for LNG Stainless steel tubes shall only be joined by stainless steel fittings Rigid fuel lines shall
53. tan alar Sacaron anita 27 452 European standards sersan ERr aaa EEr ahia E a 30 4 6 Ss mmay regulation ongoing essasi ea a a a tl eeetg acomestle 31 Aol EERI A 31 4 6 2 Other European regulations and standards under develOpMent cccessecesseecesseeseseseesens 52 4 6 3 International regulations and standards under development uu ce ccesessesesseseseeseeesseeeseeecesees 53 4 6 4 Some aspects uncovered in the current reQGulations 0 cssesessesssessssessesssessesessesessseesseeseeeees 54 4 7 Summary of North American codes regulations and standardS cocoocconiccinnononnonnnnnncnonnonnnnoos 56 4 8 Summary of Chinese regulations and standarOS ococonicconcononconennonnnonnoncnono cono cornonno no cnroronocnonr cronos 60 o LNG 2 LNG BC D4 1 Vehicle Regulations State of the Art Public REVISION HISTORY AAA AR 0 5 29 11 2013 Jes s GALLEGO IDIADA Revision and addition of final contributions and commentaries LNG BC D4 1 Vehicle Regulations State of the Art Public 1 Introduction 11 What is the LNG BLUE CORRIDORS Project The Blue Corridors project s aim is to establish LNG as a real alternative for medium amp long distance transport first as a complementary fuel and later as an adequate substitute for diesel Until now the common use of natural gas as fuel was only in heavy vehicles running on natural gas NG for municipal use such as urban buses and garbage collection trucks
54. tandard Between 1980 and 1982 a committee of the American Gas Association AGA developed a draft of a fire safety standard for vehicular fuel systems This was based on existing worldwide standards and current U S practice In late 1981 the AGA petitioned the NFPA to establish a technical committee project on the subject The normal NFPA solicitation of comments revealed sufficient response from various interested parties and the Committee on Compressed Natural Gas Vehicular Fuel Systems was established by the Standards Council in July 1982 The first edition of NFPA 52 was issued in 1984 and it was revised in 1988 1992 1995 and 1998 The 2006 edition of NFPA 52 is a complete revision NFPA 57 LNG Vehicular Fuel System Code shall apply to the design installation operation and maintenance of liquefied natural gas fuel systems on vehicles of all types to their associated fuelling dispensing facilities and to LNG to CNG facilities with LNG storage in ASME containers of 70 000 gal 265 m3 or less has been incorporated into NFPA 52 As previously commented at the same time SAE J2343 is applied in the US Its purpose is to promote safety and efficiency by making available to sellers and buyers of commercial liquefied natural gas powered medium and heavy duty vehicles a recommended practice for construction operation and maintenance of such vehicles 43 Current European L NGV Markets and Main Actors Even if in some EU coun
55. tituting the pressure relief valve which are in contact with the LNG when operating shall be compatible with the test LNG Operating specifications The LNG pressure relief valve in Class 5 shall be so designed as to withstand a pressure of 1 5 times the working pressure MPa at cryogenic temperature with the outlet closed off The pressure relief valve and pressure relief device of Class 5 shall be so designed as to be leak proof at a pressure of 1 5 times the working pressure MPa with the outlet closed off The LNG excess flow valve The materials constituting the LNG excess flow valve which are in contact with the LNG when operating shall be compatible with the test LNG The LNG manual valve The materials constituting the LNG manual valve which are in contact with the LNG when operating shall be compatible with the test LNG In order to verify this compatibility the procedure described in Annex 5D shall be used Operating specifications The LNG manual valve device in Class 5 shall be designed to withstand a pressure of 1 5 times the working pressure at cryogenic temperature It shall be designed to operate at a temperature from 162 C to 85 C LNG manual valve device requirements LNG Pe LNG BC D4 1 Vehicle Regulations State of the Art Public One specimen shall be submitted to a fatigue test at a pressure cycling rate not exceeding 4 cycles a minute as follows Hold at 162 C or lower while pressured
56. tries the experience with LNG vehicles started quite some years ago via the conversion of existing diesel trucks to run on dual fuel diesel plus NG mode it has not been until 4 5 years ago that European OEMs officially jumped into the HD LNG vehicle business by offering NLNG 2 BLUE 19 LNG BC D4 1 Vehicle Regulations State of the Art Public ex factory LNG models These are the main examples nowadays OEMs LNG trucks directly produced from the factory Iveco with dedicated spark ignited engines working with 100 natural gas 330 Hp Chart LNG tank technology Volvo Dual fuel compression ignition engines working with diesel NG blends of around 70 NG 460 Hp Chart LNG tank technology Mercedes Dedicated spark ignited engines 280 Hp use an Indox LNG tank technology Scania Dedicated spark ignited engines working with 100 natural gas 305 Hp Indox LNG tank technology Adaptations LNG trucks transformed once they leave factory Hardstaff Involved in the use of dual fuel technology in heavy road haulage vehicles in the UK and Europe Clean air power Their technology allows the diesel engine to run on Diesel and natural gas simultaneously with an average substitution rate of up to 60 HAM Transports Their main aim is the transport by road of liquefied gases only transportable by special vehicles They have adapted more than 70 vehicles Prins Autogas They have developed an innovative range of core components fo
57. ublic Texas Administrative Code Title 16 Part 1 Applicability LNG regulations in Chapter 14 Comments Texas requirements CSA B109 01 gt Natural Gas for Vehicles Installation Code Applicability Canadian Std Applies to installation servicing and repair of NG fuel systems on self propelled vehicles Other codes standards and guidelines applicable to parking structures and repair garages for LNG vehicles NFPA 88A gt Standard for Parking Structures 1998 Applicability Open enclosed basement and underground parking structures Comments No special requirements for NGVs other than reference to NFPA 52 and 57 NFPA 88B gt Standard for Repair Garages Applicability Construction and protection of as well as the control of hazards in garages used for major repair and maintenance of motorized vehicles and any sales and servicing facilities associated therein Comments NGV requirements are also included in NFPA 30A NFPA 30A gt Code for Motor Fuel Dispensing Facilities and Repair Garages 2012 Applicability Facilities dispensing both gaseous and liquid fuels at the same facility Comments Includes requirements of old 88B on repair garages International Fire Code IFC 2012 LNG 59 LNG BC D4 1 Vehicle Regulations State of the Art Public Applicability International fire code Comments Check with local fire marshal on applicability Guideline for Determining the Modifications Required for Adding Co
58. uelled vehicles Vehicles of categories M2 and M3 equipped with a LNG system shall be labelled as specified in Annex 7 see annex section The label shall be installed on the front and rear of the vehicle of category M2 or M3 and on the outside of the doors on the right hand side left hand drive vehicles left hand side right hand drive vehicles A label shall be placed adjacent to the LNG fill receptacle stating the fuelling requirements The fuelling requirements shall be as recommended by the manufacturer Further requirements No component of the CNG and or LNG system including any protective materials which form part of such components shall project beyond the outline of the vehicle with the exception of the filling unit if this does not project more than 10 mm beyond its point of attachment Proper shielding against heat of adjacent components shall be considered and no component of the CNG and or LNG system shall be located within 100 mm of the exhaust or similar heat source unless such components are adequately shielded against heat Installation of the container and or tanks The container and or tank shall be permanently installed in the vehicle and shall not be installed in the engine compartment The container and or tank shall be installed such that there is no metal to metal contact with the exception of the fixing points of the container s and or tank s When the vehicle is ready for use the fuel contain
59. uelling dispensing facilities and to LNG to CNG facilities with LNG storage in ASME containers of 70 000 gal 265 m3 or less Comments Main source of guidance for LNG vehicles but also fuelling facilities SAE J2343 gt Recommended Practices for LNG Powered Heavy Duty Trucks 2008 Applicability Provides guidance for the construction operation and maintenance of LNG powered medium heavy duty vehicles and all LNG vehicles used for public transit or commercial applications Comments Published by the Society of American Engineers SAE Primarily heavy truck recommendations but also some maintenance facility equipment and procedures DOT FTA MA 26 7021 97 1 gt Design Guidelines for Bus Transit Systems Using Liquefied Natural Gas LNG as an Alternative Fuel 3 97 Applicability Transit Facilities but useful reference for other fleets Comments FTA Federal Transit Administration Report Not only references required codes e g NFPA but also suggests additional precautions and provides general information DOT FTA MA 90 7007 95 3 gt Liquefied Natural Gas Safety in Transit Operations 3 96 Applicability Transit Facilities but useful reference for other fleets Comments FTA Federal Transit Administration Report Not only references required codes e g NFPA but also suggests additional precautions and provides general information ANSI NGV3 1 1995 gt Fuel System Components for Natural Gas Powered Vehicles Appl
60. ular Fuel Systems Code are allowed Valves Valves included in the tank must fulfil the requirements established in UNE EN 1251 Previously was demanded the national regulation described in the Real Decreto regarding equipment under pressure Receptacle It must be of Kodiak type Heat exchanger It must be associated to the tank or without exit Pressure regulator Installation according to R110 Piping Must fulfil the R110 requirements Valves Valves included in the system need to fulfil the R110 23 LNG BC D4 1 Vehicle Regulations State of the Art Public NG detector Not required Sensors According to R110 Other LNG specific components Tank vaporizer It is necessary to install an automatic valve in the vaporizer Abstract R110 R 115 R 67 UNE EN 1251 2001 ISO 12614 ISO 12617and SAE J2343 442 Sweden Fuel tank Must meet the requirements outlined in Regulation R110 In dual vehicles the diesel tank must fulfil R34 Valves According to R110 Receptacle According to R110 Heat exchanger According to R110 Pressure regulator According to R110 LNG P LNG BC D4 1 Vehicle Regulations State of the Art Public Piping According to R110 Valves According to R110 NG detector According to R110 Sensors According to R110 Other LNG specific components Prevention of fire according to R 110 National requirements for Periodical Technica
61. xperience with CNG vehicles thus all regulations and standards affecting the construction and approval of specific LNG components have been developed taking into consideration the already existing legal framework for CNG vehicles and their components Up to now all on board CNG related aspects were approved according to ECE Regulation 110 but LNG was missing in its scope Thus the Heavy Duty vehicle manufacturers have been experiencing certain issues regarding the deployment of L NGVs in most European markets where they have had to rely on national approvals to date This has certainly set a barrier as those vehicles were only recognized by those countries granting the approval causing problems for most fleet operators willing to travel across the European Union After years of experience in the use of this vehicle technology the European NGV industry addressed the need to solve the above mentioned lack of harmonization and this was partially carried out through the work of the UNECE LNG Task Force This Task Force with the cooperation of several European LNG vehicle and component manufacturers has worked for more than two years to update ECE R110 in order to include all the necessary amendments for LNG components amp systems to be approved As previously mentioned and due to the fact that ECE R110 focus is for on board vehicle equipment aspects assuring the proper connection between the vehicle and the filling station are something
62. yogenic liquid fuel and deliver it as gas to the engine with gas temperature between 40 C and 105 C The material constituting the LNG heat exchanger vaporizer which is in contact with the CNG when operating shall be compatible with the test CNG The part of the LNG heat exchanger vaporizer which is in contact with the tank is regarded as Class 5 It shall be so designed as to withstand a pressure of 1 5 times the working pressure MPa without leakage and deformation It shall be so designed as to be leak proof external at a pressure of 1 5 times the working pressure MPa LNG 43 CORRIDORS 6 if gE LNG BC D4 1 Vehicle Regulations State of the Art Public The LNG heat exchanger vaporizer has to comply with the test procedures for the Class 5 It has to comply with the water jacket freezing test Fill the part of the heat exchanger vaporizer which normally contains an antifreeze solution with water to normal capacity and expose it at 40 C for 24 hours Attach 1 m sections of coolant hose to the coolant inlet and outlet of the heat exchanger vaporizer Following the freezing conditioning conduct an external leakage test at room temperature Annex 4J Provisions on the approval of the LNG filling receptacle The purpose of this annex is to determine the provisions on the approval of the LNG filling receptacle LNG filling receptacle The LNG filling receptacle shall comply with the fol

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