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ACT 7150 ALMEDA-GENOA

HOUSTON, TX 77075
APPLIED CRYO TECH WWW.APPLIEDCRYOTECH.COM

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B B

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ACT 7150 ALMEDA-GENOA

HOUSTON, TX 77075
APPLIED CRYO TECH WWW.APPLIEDCRYOTECH.COM

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 Operating Manual

Automated LNG Mobile Fueling System

Model: 16.1K-175-LNG-ELEC-MDT

Built for
ENCANA

By
InoxCVA Cryogenic Vessel Alternatives, Inc

9528 Warren Road, Mont Belvieu, TX 77580

281-385-1204

For unit Serial Number LSP10009/16082

Revision Date: July 23, 2012
 Table of Contents

Contents
FOREWORD..................................................... 1
SAFETY SUMMARY ............................................... 2
SAFETY PRECAUTIONS FOR LIQUIFIED NATURAL GAS (LNG) ............ 2
For additional cryogenic liquid handling, storage, and transportation information,
contact: ....................................................... 2
For additional flammable cryogenic liquid handling, storage, and transportation
information contact: .............................................. 2
RECEIVE PROPER TRAINING BEFORE OPERATING .................... 3
EMERGENCY TREATMENT OF BODILY CONTACT...................... 3
SAFETY EQUIPMENT ............................................ 3
UNAUTHORIZED CONTAINERS .................................... 3
VENTILATION .................................................. 3
PART CLEANLINESS ............................................ 3
PURGE AND SPLASH HAZARDS ................................... 4
ELECTRICAL GROUND........................................... 4
GENERAL PROPERTIES AFFECTING FIRE HAZARDS ................... 4
FIRE HAZARDS DURING TRANSPORT ............................... 5
OTHER HAZARDS............................................... 6
HEALTH ISSUES................................................ 7
ENVIRONMENTAL ISSUES ........................................ 7
SAFETY EQUIPMENT ............................................ 7
UNAUTHORIZED CONTAINERS .................................... 7
VENTILATION .................................................. 8
LIFTING ...................................................... 8
PURGE AND SPLASH HAZARDS ................................... 8
MAINTENANCE ................................................. 8
WELDING AND BRAZING ......................................... 8
NO SMOKING .................................................. 9
CAUTION AND WARNING MESSAGES ............................... 9

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) i

 MAINTAIN ADEQUATE VENTILATON ................................ 9
REPLACEMENT PARTS MUST BE SUITABLE FOR LNG SERVICE .......... 9
INTRODUCTION ................................................. 10
16,113 Gallon LNG Tank Description .................................. 10
SYSTEM DESCRIPTION SUMMARY AND OPERATION OVERVIEW .......... 12
OPERATING INSTRUCTIONS ....................................... 37
Dispensing Product (filling a vehicle fuel tank) .......................... 37
Filling the Mobile Fueling Station Tank................................ 50
Warm Tank and Purging for Dew Point and Purity ............ 50
Tank Cool Down Purge Options .................................... 56
Cold Vapor Cool Down in Bottom of Tank and out Top ........ 57
Least Preferred Cool Down Method is Using Liquid .......... 57
Filling the Mobile Fuel Station 16.1KTank When it is Cooled
Down ...................................................... 58
Filling Refueler Using Optional External On-Load Pump ................... 62
Saturation Operation ............................................ 74
To perform a saturation operation ................................... 75
Daily Inspections and Maintenance.................................... 78
Weekly (or more often if needed) Inspections and Maintenance ............... 79
Monthly to Quarterly Inspections and Maintenance as Required ............... 81
As Required Maintenance .......................................... 81
Annual or as Required Inspections and Maintenance ....................... 81
SPARE PARTS .................................................. 88
TROUBLE SHOOTING ............................................ 94
APPENDIX A – Piping Schematic Revised 6-22-2012 ....................... A
APPENDIX B – ELECTRICAL SCHEMATICS (INOX-CVA PROPRIETARY
INFORMATION – COPYRIGHT)....................................... B
APPENDIX C – PNEUMATIC SCHEMATIC .............................. B
APPENDIX D – TC-34 Submerged Pump Curve, and Optional LNG @ 6000 PRM & TC-
30 External Pump @ 4400 RPM. TC-34KA Submerged Pump Curve LNG @ 7200
RPM. .......................................................... D
APPENDIX E – Liquid Level Charts .................................... E

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) ii

APPENDIX F – GENERAL ARRANGEMENT DRAWING ..................... F
OTHER APPENDICES ............................................. G

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) iii

 FOREWORD

This manual provides information on the Cryogenic Vessel Alternatives model CVA
16.1K-175-LNG-MDT mobile liquid natural gas fueling unit. Natural Gas, Refrigerated
Liquid, UN1972 is liquid methane. This manual provides information on safety,
operating procedures, maintenance, and troubleshooting.

Use of the equipment without regard to the information herein could result in
potential safety and product hazards, reduced equipment life, and higher operating
costs. This manual provides guidance for the owner/operator and should be
incorporated into the fleet operation, safety, and maintenance programs. This
manual does not replace those programs. Rather, it augments them.

This manual should not be considered as a training manual or be relied on for extensive
repairs. The manual is limited to proper utilization by properly trained personnel.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 1

 SAFETY SUMMARY

SAFETY PRECAUTIONS FOR LIQUIFIED NATURAL GAS (LNG)

Natural Gas is a flammable gas. The National Fire Protection Association (NFPA) has set
up guidelines when working with Liquefied Natural Gas in the standard NFPA 59A
Production, Storage, and Handling of Liquefied Natural Gas (LNG).

What follows are some general guidelines for handling flammable cryogenic liquids. This
is by no means a comprehensive list, and it is recommended that users of LNG obtain the
current edition of NFPA 59A for more information.

1) Only qualified, trained personnel should operate a container with flammable cryogenic
liquids in it.

2) Fire protection should be provided at all facilities used for flammable cryogenic liquids.

3) A detailed emergency procedure manual shall be prepared to cover potential

emergency conditions, including coordination with local authorities.

4) Smoking and non-process ignition sources within 100 ft of the container are prohibited.

5) Welding, cutting and other operations should be done at times and places specifically
authorized and in accordance with the provisions of NFPA 51B.

6) Because an explosive mixture could develop with gas fires, the fuel source should be
shut off first before extinguishing the fire.

For additional cryogenic liquid handling, storage, and transportation information,

contact:

Compressed Gas Association, Inc.

4221 Walney Road, 5th Floor
Chantilly, VA 20151
703-788-2700
For additional flammable cryogenic liquid handling, storage, and transportation
information contact:

National Fire Protection Agency

1 Batterymarch Park
Quincy, Massachusetts, 01269
617-770-3000

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 2

RECEIVE PROPER TRAINING BEFORE OPERATING
Do not attempt to operate this equipment without receiving proper training as
established by your company’s training procedures. Although the system was
designed for operator-friendly operation, with instructions, warnings, prompts,
and explanations that appear as needed, or by pressing an INFO button, you
must never operate the system without receiving proper basic LNG training, and
specific training on how to properly operate this system.

EMERGENCY TREATMENT OF BODILY CONTACT

In the event of injury resulting from bodily contact with Liquid Natural Gas (LNG)
remove victim from the exposure immediately. Do not attempt to rewarm injured
tissue, as this should be accomplished by proper medical personnel. Make the
victim as comfortable as possible, keep victim dry and warm and transport to an
emergency room of a hospital or clinic as soon as possible. Upon arrival, advise
medical personnel of the LNG injury exposure.

SAFETY EQUIPMENT

Wear ear and eye protection during load transfer, venting, and maintenance
operations. Wear gloves and clean protective clothing.

UNAUTHORIZED CONTAINERS

Never put LNG in any other container (e.g. thermos bottle) that was not
specifically designed for containment of LNG. All LNG containers must include
safety pressure relief devices. When warmed, LNG will expand rapidly and build
pressures to extremely high levels. Pressure buildup without safety devices may
result in an explosion and injury or death.

VENTILATION

Adequate ventilation must be provided for personnel for container functions such
as transfer operations, filling, draining, purging, painting, and cleaning.

PART CLEANLINESS

Container is cleaned for LNG service using liquid oxygen cleaning procedures
and liquid nitrogen inspection procedures.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 3

PURGE AND SPLASH HAZARDS

When discharging cryogenic liquids from hoses, blow down lines or drain valves
slowly to avoid being splashed by the cryogenic product.

ELECTRICAL GROUND

Always clip an electrical static ground cable so that unit is connected to an earth
ground, or so that two units are grounded together, before filling or off-loading.

GENERAL PROPERTIES AFFECTING FIRE HAZARDS

LNG is a refined and consistent product with none of the problems associated with
corrosive effects on tank storage associated with water vapor and other contaminants.
But the cryogenic temperature makes it extremely difficult or impossible to add an
odorant. Therefore, with no natural odor of its own, there is no way for personnel to
detect leaks unless the leak is sufficiently large to create a visible condensation cloud or
localized frost formation. It is essential that methane gas detectors be placed in any
area where LNG is being transferred or stored.

The cryogenic temperature associated with LNG systems creates a number of

generalized safety considerations for bulk transfer and storage. Most importantly, LNG
is a fuel that requires intensive monitoring and control because of the constant heating
of the fuel which takes place due to the extreme temperature differential between
ambient and LNG fuel temperatures. Even with highly insulated tanks, there will always
be a continuous buildup of internal pressure and a need to eventually use the fuel vapor
or safely vent it to the atmosphere. When transferring LNG, considerable care has to
be taken to cool down the transfer lines in order to avoid excessive amounts of vapor
from being formed.

The constant vaporization of the fuel also has an interesting effect on the properties of
the fuel, unless it is a highly purified form of LNG. The methane in the fuel will boil off
before some of the other heavier hydrocarbon components such as propane and
butane. Therefore, if LNG is stored over an extensive period of time without withdrawal
and replenishment the methane content will continuously decrease and the actual
physical characteristics of the fuel will change to some extent. This is known as
“weathering” of the fuel. The higher the purity level of methane, the less weathering will
occur.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 4

Another consideration is that under low temperatures, many materials undergo changes
in their strength characteristics making them potentially unsafe for their intended use.

As before, many of these potential issues have been identified and addressed in the
various codes that have been developed by the NFPA and under the Uniform Fire
Code.

For example, the NFPA has the following national standards and codes applicable to
LNG:

NFPA 59A—Standard for Production, Storage, and Handling of Liquefied Natural Gas
NFPA 57 (draft)—Standard for Liquefied Natural Gas Vehicular Fuel Systems (final
code expected to be published in 1995).

FIRE HAZARDS DURING TRANSPORT

The double walled construction of the LNG vessel is inherently more robust than the
equivalent design for transport of other liquid fuels. Therefore, the transport of LNG is
safer from the perspective of fuel spills resulting from a tank rupture during an accident.
A rupture of the outer vessel would cause the loss of insulation and result in an
increased venting of LNG vapor. While this is of concern, it is relatively minor compared
to the prospect of an LNG spill.

An explosion of an LNG container is a highly unlikely event that is possible only if the
pressure relief equipment or system fails completely or if there is some combination of
an unusually high vaporization rate (due to loss of insulation) and some obstruction of
the venting and pressure relief system preventing adequate vapor flow from the inner
pressure vessel with a resultant pressure build up. If the pressure builds up to the point
where the vessel bursts, the resulting explosion is known as a BLEVE (Boiling Liquid
Expanding Vapor Explosion) with the container pieces propelled outward at a very high
velocity. This is a highly unlikely event due to the extensive requirements for pressure
relief, including pressure relief valves or burst discs that are built into the design codes.
(There have been no reports in the literature reviewed of and BLEVE occurring with
LNG).

In the event that the LNG vessel is ruptured in a transport accident and the LNG is
spilled, there will be a high probability of a fire because a flammable natural gas
vapor/air mixture will be formed immediately in the vicinity of the LNG pool. In an
accident situation, there is a high likelihood of ignition sources due to electrical sparking,
hot surface, or possibly a fuel fire created from the tanker truck engine fuel or other
vehicles involved in the accident. The vapor cloud from an LNG pool will be denser that
the ambient air; therefore it will tend to flow along the ground surface dispersed by any
prevailing winds.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 5

When spilled along the ground or any other warm surface, LNG boils quickly and
vaporizes. As the liquid vaporizes it continues to warm and soon rises, unlike heavy
propane vapor which stays along ground level or sinks with low places.

A high volume spill will cause a pool of LNG to accumulate and the boiling rate will
decrease from an initial high value to a low value as the ground under the pool cools.
The heat release rate from an LNG pool fire will be approximately 60% greater than that
of a gasoline pool fire of equivalent size.

OTHER HAZARDS

LNG has a unique safety hazard among the alternative motor fuels because of the
potential exposure of personnel to cryogenic temperatures. Workers can receive
cryogenic burns from direct body contact with cryogenic liquids, metals, and cold gas.
Exposure to LNG or direct contact with metal, i.e. piping, at cryogenic temperatures can
damage skin tissue more rapidly than when exposed to vapor. It is also possible for
personnel to move away from the cold gas before injury.

The risk of cryogenic burns through accidental exposure can be reduced by the use of
appropriate protective clothing. Depending upon the risk of exposure, this protection
can range from loose fitting fire resistant gloves and full-face shields to special extra
protection multi-layer clothing, including long sleeve shirts and pants without cuffs.

Another unusual hazard associated with aged LNG will arise in the unlikely event that
there is a large spill of LNG onto a body of water. This could occur in an accident
situation involving an LNG transport vehicle container rupture and spill into an adjacent
water body. The hazard is known as a “rapid-phase transition” (RPT—in this case a
rapid transformation from the liquid phase to vapor (due to the effective heat transfer
from the water to the LNG). If significant vaporization occurs in a short time period, the
process can, and usually does, resemble an explosion.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 6

HEALTH ISSUES

The principal constituents of natural gas, methane, ethane, and propane, are not
considered to be toxic. The American Conference of Government Industrial Hygienists
(ACGIH) considers those gases as simple asphyxiate, which are a health risk simply
because they can displace oxygen in a closed environment. The Occupational Safety
and Health Administration (OSHA) have set a time-weighted average (TWA) personal
exposure limit (PEL) of 1,000 parts per million (ppm) for propane. A number of the
minor constituents of natural gas have ACGIH listed threshold limit values (TLVs)
including butane – 800 ppm, pentane – 600 ppm, hexane – 50 ppm, and heptane – 400
ppm. The effective TLV for an average natural gas composition, considering all of these
limits, is about 10,500 ppm.

Unlike CNG, LNG cannot be odorized; therefore, there is some concern about the ability
of personnel to detect TLV concentrations. This is another reason to ensure that
methane detectors are in place wherever personnel may be exposed.

ENVIRONMENTAL ISSUES

There are no significant environmental hazards associated with the accidental

discharge of LNG. Un-combusted methane is considered to be a greenhouse gas
approximately 23 times worse than carbon-dioxide.

LNG if released to the environment will quickly return to its gaseous state and rise under
normal atmospheric conditions. If LNG is spilled onto the ground or on water, it
vaporizes quickly, leaving no polluting residue.

SAFETY EQUIPMENT

Wear ear and eye protection during load transfer, venting, and maintenance operations.
Wear cryogenic gloves and clean protective clothing.

UNAUTHORIZED CONTAINERS

Never put liquid cryogens in any container (e.g. thermos bottle) without proper safety
devices. When warmed, liquid cryogens will expand rapidly and build pressures to
extremely high levels. Pressure buildup without safety devices may result in an
explosion possibly resulting in injury or death.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 7

VENTILATION

Adequate ventilation must be provided for personnel for functions such as transfer
operations, filling, draining, purging, painting, welding, brazing, and cleaning. Nitrogen,
Argon and Triflouromethane are colorless and odorless inert gases, which can dilute air
to unsafe oxygen levels. Respiratory and asphyxiation hazards can exist in confined,
non-ventilated spaces. Natural Gas, Ethylene and Ethane are flammable gases that
can fuel fires or form explosive mixtures. Oxygen and Nitrous Oxide, though not
flammable can vigorously accelerate the burning of combustible materials.

LIFTING

Equipment used in lifting and moving the container must be of the proper type and
sufficient rating to handle the weights involved. The tank or unit should not be lifted
when full of product. Care must be taken when lifting in order to not collapse the outer
vacuum jacket.

PURGE AND SPLASH HAZARDS

When discharging cryogenic liquids from service hoses, blow down lines or drain
valves, open the valves slowly to avoid being splashed by the cryogenic product.

MAINTENANCE

A preventative maintenance program must be implemented to assure that necessary

routine maintenance and inspection procedures are performed. Inspect structural and
safety equipment integrity for cracks and worn parts. Loose components must be
secured. Leaking, missing, or damaged parts must be replaced or repaired.

WELDING AND BRAZING

Before welding or brazing, the tank must be purged and analyzed, and deemed safe.
To avoid damage to electronic components, disconnect both leads on the battery before
welding on this equipment. Welding or brazing operations produce heat, metal fumes,
injurious radiation, metal slag, and airborne particles. Proper protective equipment must
be worn before welding or brazing. Never look directly at the arc when welding or at the
flame during brazing. Never attempt welding or brazing operations near Teflon
components (e.g. anti-seize tape). Teflon components deteriorate at high temperatures
and emit poisonous gases. Proper ventilation is a must when welding or brazing.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 8

NO SMOKING
Smoking is not permitted anywhere within 100’ of the LNG refueling system.

CAUTION AND WARNING MESSAGES

This manual contains additional cautions and warnings which must be heeded to
minimize the potential for equipment damage or injury. CAUTION messages are
generally provided to draw attention to the possibility or probability of equipment
damage. WARNING messages are provided to draw attention to the possibility or
probability of personal injury, illness, or death. Caution and warning message displayed
on decals or on display screens on the unit must always be observed.

NO SMOKING or open flame in any area where LNG is stored, handled, or used.

MAINTAIN ADEQUATE VENTILATON

Enclosed areas containing LNG equipment should be ventilated to prevent accumulations

and thereby minimize combustion hazards.

REPLACEMENT PARTS MUST BE SUITABLE FOR LNG SERVICE

Make no substitutions for recommended spare parts. Also, be sure all replacement parts
are thoroughly "Cleaned for Oxygen Service" in accordance with Compressed Gas
Association (CGA) Pamphlet G-4.1 "Cleaning for Oxygen Service" or equivalent industrial
cleaning specifications. All components must meet both temperature and pressure use
requirements.

All electrical or electronic components must meet the voltage and amperage requirements,
and most importantly meet the explosion proof requirements of Class 1 / Division 1 if used
in the classified areas.

All pneumatic components must meet DOT requirements where necessary. All other
pneumatic components must meet the design requirements with safety margin.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 9

INTRODUCTION

This manual provides information on the Cryogenic Vessel Alternatives model CVA
16.1K-175-LNG-MDT mobile liquid natural gas fueling unit. Natural Gas, Refrigerated
Liquid, UN1972 is liquid methane. This manual provides information on safety, operating
procedures and basic maintenance. Everyone using or maintaining this system must
receive additional classroom and hands-on training by a qualified trainer.

Use of the equipment without regard to the information herein could result in potential
safety and product hazards, reduced equipment life, and higher operating costs.

This manual provides guidance for the owner/operator and should be incorporated into
the fleet operation, safety, and maintenance programs. This manual does not replace
those programs. Rather, it augments them. This system is composed of many sub-
systems and components. Manuals for those components are included in the appendix.
Please refer to those system manuals for maintenance and schedules.

16,113 Gallon LNG Tank Description

Model CVA-16.1K-175-TM
Service LNG
Net Capacity 16,113 USG

UNIT DIMENSIONS

Overall height 12’

Overall length 53’
Maximum width 8.5’
Tare Weight (approx.) 39,500 lbs.

OUTER VESSEL DATA

Material A-1011 GR 50
Outside diameter 102”
Construction Code US DOT, CGA341, MC-338
Thermocouple tube Hastings DV-6R

INNER VESSEL DATA

Material SA-240 GR 304

Inside diameter 95”
Design Pressure 175 psi

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 10

 Baffles 0
Radiology RT-2
Manway 1

INTERNAL PIPING DATA

Material / sch. 40 SA 312 GR 304

Top Fill 2” pipe

Sparger Line 2” pipe
Int. Vent Line 2” pipe
Gauge Lines ¼” pipe
Pump Outlet 1” pipe
Pressure Build 1” pipe
Recirc Line 1” pipe
Vent Pipe 2” pipe
Full Trycock 3/8” pipe
Recondenser line 1/2” pipe

INTERNAL & ANNULAR PIPING

Material 304 Stainless

Pipe Schedule Sch. 10 w / sch. 40 ext. penetrations

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 11

SYSTEM DESCRIPTION SUMMARY AND OPERATION OVERVIEW

Let’s take a virtual tour of the system, and look at the front of the system, then work our
way back. While we are looking around we will chat about the major systems
components and generally how the system works.

Mobile LNG Refueler

The LNG Refueler produces 110 volts from a 480-volt / 3-phase current supplied to the
unit. 24 and 12 volt DC power are also used on this system.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 12

Un-classified electrical area at front of trailer. Front control panel, fire extinguisher, card
reader inside tool box, Micro Motion transmitter/totalizer on driver’s side front fender
(the modem / GPS will either be located in the tool box with the card reader, or on the
right side of the fender. Overhead in the front impoundment area are a 12-volt
explosion-proof light, a 110-volt explosion-proof light, a warning siren and a methane
detector.

The air compressor may be 208 volt (two 110-volt legs) or 480 volts/3 phase. The air
compressor provides air to actuate the automatic valves. A shop air hose is also
provided at the rear of the unit for the operator’s use in drying off frost or moisture from
the fill nozzle which forms during dispensing operations. It is important to blow the
nozzle (and receiving fuel tank receptacle, if necessary) dry to avoid introducing
contamination into the fuel tank. Drying also prevents the nozzle from freezing onto the
receptacle.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 13

Compressed air hose to blow frost and moisture from fill nozzle before filling vehicle
tanks.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 14

 Air compressor mounted on roadside front fender provides air to operate automatic
valves, and provides air to air hose to clean and dry off frosted or wet receptacles and
fill nozzles.

A green 24-volt indicator light on the front enclosure will illuminate when the key is
turned on. If there is power, but the temperature indicator light is not on that indicates
the internal heaters are warming the interior of the enclosure. Once the minimum
temperature is achieved the TEMP OK light will illuminate and the PLC and VFD will
boot up.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 15

Temp OK light to the right of the red Emergency Stop button, indicates that the system
can begin booting up. Heaters in the enclosure will warm the system when it is cold.
The system will not boot up until the temperature is OK. Note, the optional black knob is
used to select the optional external on-load pump (position 2) or the submerged
dispense pump (position 1).

There is one 12-volt explosion proof light located overhead near the front of the unit.
When the key to the front panel is turned on this work light can be turned on. Besides
the 12 and 24-volts at the front, after turning the key on nothing else in the unclassified
or classified areas of the system will be energized until the flame detector and the two
methane detectors (one located overhead at the front and one overhead at the rear),
boot up indicating the system is safe. This power-up takes about 60 seconds. The
warning siren will chirp when the safety system is ready, and the green Area Safe light
will light up. Systems using 12 or 24 volt DC power will begin powering up.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 16

 Explosion-proof light and warning siren. Siren goes off at 45% LEL and the system
automatically emergency stops.

Red flame detector located overhead at rear of trailer. A blinking green LED indicates it
is working properly.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 17

 Methane detectors are located overhead, one at the front and one at the rear if the
trailer. Status codes are displayed in the window. Message codes are included on a
decal located nearby.

Front control panel – When key is turned on the green 24-volt light above key
illuminates. After 60 seconds the green AREA SAFE light to the right of it will illuminate
(the siren will chirp). You can then press the 115 VAC CONTROL ON button to send
power to the transformer and the rest of the system will boot up.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 18

Other systems will now begin powering and booting up (i.e. the Variable Frequency
Drive (VFD) that you can see through the window in the front enclosure, the
Programmable Logic Controller (PLC) in the front enclosure, the Panel View display in
the rear enclosure and the air compressor will start. A green Power On light will
illuminate inside the window on the rear enclosure, directly below the Panel View
display. NOTE however that when the ambient temperature is low, heaters in the front
and rear enclosures will power on first and heat the enclosures until they are warm
enough for the liquid crystal displays and other electronics, then a green TEMP OK light
will light up on the front panel indicating that it will then boot up, and the same on the
rear enclosure. The TEMP OK light on the rear enclosure is located inside the
enclosure and can be seen directly below the Panel View display through the round
window.

Green Power On light indicates that system has power. Once the minimum
temperature is achieved the Temperature OK light will illuminate and the Panel View will
boot up.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 19

The credit card reader (if your system has one), the Coriolis flow metering system
transmitter, the modem/GPS (if your system has these items) will also be powering up if
they have not already done so.

Customer specific (optional) card reader. The system will go no further than
recirculating if the card has not been swiped to authorize the transaction.

There are four (4) Emergency Stop (E-stop) buttons on the mobile fueler; one at each
corner. The one at the front driver’s side is on the front enclosure. Pressing these will
shut everything off except the 12-volt explosion-proof light up front and the 12-volt red
warning light in the back.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 20

 Four Emergency Stop buttons are located at each corner of the trailer. The one at the
driver’s side front is located on the front enclosure panel. Pressing an E-STOP will shut
everything off except the Red Beacon Light.

Should either the front or rear methane detectors ever sense 25% of the Lower
Explosive Limit (LEL) of methane the red flashing light located high at the rear of the
system will come on. Should the concentration reach 45% of the LEL the siren will also
come on and the Area Safe system will automatically emergency stop, shutting down
everything (engine and all equipment) except the Safety System (detectors, red light,
and siren and their power source).

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 21

 At the rear of the trailer, mounted overhead are the red warning beacon, 110-volt light,
flame detector (red), methane detector, and another 110-volt light.

Red strobe light goes off when 25% of LEL is sensed, and lights when the siren goes off
at 45% LEL, and when an Emergency Stop button is pressed.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 22

Wheel chock blocks are provided for safety to block the tires. One fire extinguisher is
provided at the front of the unit and one at the rear.

Exiting the tank are two explosion-proof electrical condolets in-line before each is a
pressurized electrical pass through fitting, which provide the means for sealing the tank
pressure while letting the electrical wires to the submerged pump enter the tank.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 23

Two (redundant for safety) electrical condolets in-series, with pressurized electrical
pass-through fittings right before each, provide the means for electrical power to enter
the tank and pass through the vacuum space and into the inner vessel to the
submerged pump. One condolet is open with the 480-volt / 3-phase wires showing in
this photo.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 24

An optional external pump used to load product into the mobile refueler may be located
frontward of tandem axles.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 25

A selector switch permits the operator to choose between the submerged dispense
pump at position 1 or the external up load pump at position 2 (0 is off). A potentiometer
knob (that comes with this option) on the rear enclosure is used to control the speed of
the external pump.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 26

A transformer is located on the curbside front fender. It takes some of the 480-volt / 3-
phase current and transforms it to 115 volts which is used for the other three outdoor
work lights, enclosure heaters, and for many other systems. A 600-volt to 480-volt
transformer is used on Canadian units to transform the standard 600-volt shore power.
12 volt power is taken from the battery and a battery charger. A power converter and
power supplies provide the necessary 24 volt power.

Each day the operator should pull the water drain cables on the bottom of the air
compressor tanks until no visible water sprays out. From the air compressor you can
see that the air line runs to an electric air dryer. Pressure switches located by the air
dryer permit the PLC controller to know that there is sufficient air to actuate the valves.
Messages about the air pressure are displayed on the rear display, i.e., “system building
air pressure” or “air pressure OK”. Since this is downstream of the air dryer its air
should be dry. But also give that water drain cable a pull to verify the air is dry. Wet air
will cause problems with the actuated valves, especially in cold weather.

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Electric air dryer – dries air from compressor tank which is then stored in the secondary
air tank located under the King-Pin deck, to supply dry air to the valves and operator’s
air hose.

Once everything is powered up the rear enclosure display will indicate that the system is
in Power On or standby mode, waiting for you the operator to give it a command. Three
Informational messages and prompts scroll repeatedly should you ever have a question
on safety or what to do. Messages indicate what is going on with the system, e.g. if it is
building tank pressure, or compressor air pressure, or if the systems shut down for a
reason. Pressing and holding down the INFO button will also let you know what is
going on.

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(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 29
 Explosion-proof rear enclosure – Instructive displays prompt operator on what to do,
and informs of systems status, faults, errors, and help and information messages. The
potentiometer knob on the bottom center row comes with the external on-load pump
option and is used to control pump speed (the Start and Stop Fill buttons start and stop
the On-Load pump when the On-Load pump is selected on the front control panel).

To perform a normal dispense operation the operator needs only press the START
button to start the system. As soon as all systems are ready (pressure, pump has
caught prime and is recirculating and flow meter is cooled down) the display will prompt
the operator to press the START button a second time to start the fill. When the tank is
full the system will automatically stop. The operator can fill a second tank on a vehicle,
or press STOP to terminate the operation.

Rear Panel View displays safety hints, instructions, status, warnings, and information for
the operator. Examples of some of the typical displays follow:

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 First of three initial screens that will continually scroll. After they have all scrolled
through once the operator may press the START button to prepare the system and then
the pump will start and catch prime.

Operator reminder screen, 2 of 3 initial screens.

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 Operator reminder screen, 3 of 3 initial screens.

Advises that air compressor pressure is good and system is building subcool tank
pressure – then pump will start.

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 Example of system messages – this would appear if the flow meter cool down valve
failed to open.

Example of help message when INFO button is held down.

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Before starting the pump the system will build a little head pressure to suppress boiling
of the liquid in the vessel.

With optional external up-load pump you will be reminded to put the pump selector
switch in the correct position if left off.

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 Pump caught prime and is recirculating. Flow meter is cooling down. When cool the
display will flash a message for the operator to press the START button again to
commence dispensing.

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 After the pump is started and prime is caught the system will recirculate for 5 minutes
and then shut down if no further action is taken. After a fill automatically stops, or after
the operator stops a fill, the pump will continue to recirculate for 5 minutes and then will
automatically shut off.

Description of parameters displayed at bottom of rear panel:

TKL TANKS LEVEL (Actual inches of LNG inside the tank, not water column
inches of product shown on the Liquid Level Gauge.

PDP Pump Discharge Pressure

RATE Flow Rate in gallons per minute

VOL When running the actual 0 PSI equivalent gallons of product in the tank
are displayed. The saturated product is compensated to the number of
gallons you can sell. This value is not for legal sale.

TKP Tank Pressure

FMT Flow Meter Temperature

SAT Saturation Pressure—initially the value is estimated based on tank

pressure as soon as the system is recirculating and cooled down. The

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 Saturation Pressure is calculated based on the actual temperature of the
liquid.

TSCP Target Sub-Cool Pressure—this is the pressure value the tank pressure
must increase to before the pump will start and catch price and recirculate.
Due to the rounding of numbers you must be patient.

OPERATING INSTRUCTIONS

Dispensing Product (filling a vehicle fuel tank)

1. Set parking brake.

2. Set chocks and block wheels.

3. Walk around unit doing a visual and listening inspection of the system.

4. If dark, turn on working light (12-volt explosion-proof only will come on at front of
unit).

5. Insert key into switch on front control panel and turn to ON position.

6. Wait for about (60) sixty seconds until horn chirps and the green Area Safe light on
the front panel is lighted, letting you know that the methane and flame detectors
have booted up and the area is safe for you to continue.

7. Press the green 115 VAC CONTROL BUTTON (you do not have to hold it in). You
will hear the air compressor start and will see the variable frequency drive (VFD)
located inside the window on the front enclosure boot up. The air dryer will cycle as
needed when powered up. NOTE: in cold weather heaters will automatically come
in inside the front and rear panels. Both enclosures have to achieve a specified
temperature until the systems will boot up. Once the rear Panel View display is
powered up you can read and follow the instructions to perform a fill operation.

8. Connect the static ground cable clamp to a proper grounding lug on the receiving
fuel tank.

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 Always connect the static ground to receiving vehicle before commencing product
transfer operations.

9. Check the fuel gauge on the receiving vessel and determine the approximate
quantity you expect to dispense based on the fuel tank size.

10. Look at the vehicle fuel tank pressure gauge. In order to dispense product the
vehicle tank pressure must be 25 to 50 psi lower than the pump’s discharge
pressure. The pump can discharge at 150 psi plus the tank pressure. For example,
if the tank pressure is 25 psi then the pump discharge pressure will be 175 psi, and
the receiving vessel will have to be lower than 150 psi minimum (lower is better due
to warm hose flashing.) If the tank pressure is 75 psi the pump’s discharge pressure
will be 225 psi and the receiving vessel pressure must be below 200 psi.

Follow your company’s procedures when venting a tank. Methane is reported to be

a greenhouse gas 23 times worse than carbon-dioxide. Venting to the atmosphere
is not recommended.

Some vehicle tanks are vented to the atmosphere at the vehicle. Connect the ½”

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 vent hose (HS-2) with the 10 GPM nozzle shown below to the vehicle tank vent port
and vent to the atmosphere or vent into the system’s tank by selecting the position of
the diverter valve handle, DV-1. If there is no check valve on the end of the vent
hose, be sure and vent to atmosphere for a few seconds before venting (and
pushing air in hose) into station tank.

10 GPM nozzle for venting back into supply tank

Westport tanks can be vented using the dispense hose with a 3-way L-port valve (V-
12). This valve allows the dispense hose to act as a vent hose by opening the vent
valve on the Westport tank and switching the lever on V-12.

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 3-way, L-port valve, V-12.

11. At the front of the unit swipe your card if your system has a card reader. This will
reset the delivery total to zero and authorize a transaction. If your unit does not
have a card reader, press and hold down the RESET button on the rear enclosure
for five seconds to reset the batch total on the rear display and on the front Mirco
Motion display to zero.

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 Initial screen on rear Panel View display.

Second screen of three with standard operator instructions.

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 Third of three initial screens that cycle continuously with helpful information until the
START button is pressed.

12. Press the green START button on rear control panel. The system will prepare to
start the pump by building a small amount of “Target Subcool Pressure (TSCP) to
suppress the liquid from boiling and to push the liquid into the pump to provide the
pump’s required Net Positive Suction Head pressure. The system will also make
sure there is sufficient air pressure to actuate the valves, and at least 12 physical
inches of liquid in the tank (to keep the pump submerged) before starting the pump.

Once the air pressure and TSCP minimum values are achieved the pump starts and
ramps up and will catch prime and recirculate and begin cooling down the Coriolis
flow meter. The Flow Meter Temperature (FMT) is displayed on the bottom of the
screen. When the flow meter minimum temperature / time are achieved the display
will flash PRESS START to start a dispense operation. The system will recirculate
for (5) five minutes and then shut off automatically if no action is taken.

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 When the START button is pressed the system will prepare itself for pumping by
building subcool tank pressure, then the pump will start and catch prime and
recirculate at idle speed while cooling down the flowmeter.

The flow meter is cooling down. The Flow Meter Temp in this photo is -28 F.

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13. Connect dispense hose to receiving vehicle tank. Make sure both the receptacle
and nozzle are clean and dry. Use the shop air hose on the back of the delivery unit
to blow the receptacle and nozzle dry and clean.

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 Connect fill nozzle to vehicle receptacle.

14. Press the green START button a second time when the display directs and the
pump speed will ramp up to full speed and then valves will sequence and change
and you will see the dispense hose begin to frost up and see the flow rate (RATE)
and total (TOT) on the bottom of the display begin to count.

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 When START is pressed again the pump ramps up from idle to full speed (7200
RPM) and will then soon start filling and the flow rate will be displayed (0.0 in this
photo – almost to start flowing).

Filling at 44 gallons per minute. 5 gallons dispensed so far.

15. Press the red STOP button to stop the fill manually, or wait for the system to auto-
stop when the receiving vessel is full. Pressing the STOP button, or allowing the

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 system to auto-stop will put the system back into recirculation mode, allowing you to
move the vehicle to fill a second tank if it has one. NOTE the system will only
recirculate for (5) five minutes and will then shut off if no action is taken.

System can be stopped by pressing the STOP button (as in case show above), or
the system will autostop when the vessel is full. The pump will slow down to idle
speed and recirculate for five minutes and then will shut off automatically if the
operator does not fill a second tank on the same delivery ticket; or the operator
presses STOP to stop the pump to complete the transaction.

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 Press Start again if the vehicle has a second tank to fill.

Press STOP to stop the pump and end the transaction.

16. If you do not have dual tanks, always press the STOP button to stop the pump and
end the dispense operation. The system will go back to the Power On Mode.

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 Pressing the Stop button now will conclude the transaction.

17. Remove the hose from the vehicle tank and stow. Connecting the hose to the
Station Hose Top Fill Receptacle, HC-6, will permit the pressure from boiling liquid in
the dispense hose to equalize back into the system’s tank.

Immediately after disconnecting the fill nozzle and hose from the vehicle fuel tank
connect it to the fill receptacle on the refueler so liquid vaporizing in the hose can be
relieved into the tank to avoid lifting the safety relieve valve on the dispense hose.

18. Stow the vent hose, if used.

19. Stow the static ground cable.

20. Complete the credit card transaction / print the delivery receipt.

21. Stow the wheel chock blocks.

22. Note there is an air suspension dump valve located at the rear of the trailer. Always
make sure it is closed and the suspension is raised before moving the trailer.

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Filling the Mobile Fueling Station Tank

The tank must be purged to acceptable purity levels and a warm tank must be cooled
down prior to filling.

Warm Tank and Purging for Dew Point and Purity

The procedures outlined below describe how to cool down warm tank prior to filling.
Cooling a tank can be a part of the purging operation, or you may accomplish both
concurrently.

NOTE: The unit has to be connected an external 480-volt / 3-phase power supply to the
Shore Power receptacle (to permit operation of valves for the purging operation).

A critical point to remember is that when purging with cold vapor, the exiting vapor will
warm as it cools the metal of the inner vessel. However, you must obtain the required
dew point value before the exiting gas being monitored falls below freezing. Otherwise
ice crystals will fall out of the air into the bottom of the tank, providing a false dew point
reading. Therefore you should monitor the venting gas temperature as well as dew
point and purity.

1. Set parking brake.

2. Set chocks and block wheels.

3. Connect an external 480-volt / 3-phase power cord to the Shore Power receptacle
located on the curbside of the trailer.
Connecting Alternate 480-volt 3-Phase Sho

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 re Power to be able to open and close valves for the purging operation. Test pump
motor rotation direction and air compressor rotation direction. Switch any two legs of
the power if the direction is reversed.

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 You must verify that the pump is rotating the correct direction; and that the air
compressor for systems with 480-volt air compressors is also rotating the correct
direction. Even with the pump motor rotating backwards you will see some pump
discharge pressure – but if it is below normal immediately stop the pump and
disconnect the power, then swap any two legs on the input power to change the
motor rotation direction.

4. Walk around unit doing a visual and listening inspection of the system.

5. If dark, turn on working light (12-volt explosion-proof only will come on at front of
unit).

6. Connect static ground cable between trailer and warm vapor supply source.

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 Always connect the static ground to the supply source or to earth ground before
commencing product transfer operations.

7. Insert key into switch on front control panel and turn to ON position. Wait 60
seconds until horn chirps and the green Area Safe light on the front panel is lighted,
letting you know that the methane and flame detectors have booted up and the area
is safe. You will have sufficient battery power to the Safety System sensors.

8. Connect fill hose to vapor supply source and to trailer Top Fill connection, HC-3 (if
filling from an LNG fuel station pump connect to HC-6 fill receptacle).

9. Connect vapor recovery hose to HC-2, if you are able to recover any vapor instead
of venting it. If you do intend on recovering vapor, to avoid contamination to the
supply source, purge the hose on the return side before opening V-19, the Vapor
Recovery valve.

10. Open V-18 bleed valve.

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11. Crack open supply source vapor valve and purge through the hose to eliminate any
humid air contamination for one minute, then close Bleed Valve V-18.

12. All piping circuits, as well as the tank, need to be purged. All automated valves will
need to be opened via a manual control screen on the rear display. At the rear
control panel simultaneously press and hold down both the START and STOP
buttons at the same time. A screen will appear showing the automated valves.
Pressing the INFO button will increment through each valve. When a valve is
highlighted press START to open it or STOP to close it. For the purge operation,
first make sure the Fill hose is properly attached to the receptacle on the unit. Then
Open all automated valves and leave them open throughout the purge operation.

Pressing the INFO button will increment through each valve. Press START to open
a valve or press STOP to close one.

13. Carefully loosen tubing fittings on dead end circuits only enough to let them leak and
purge over the threads. Be sure to tighten and leak check all fittings when finished
with the purge operation. Note: before loosening the tubing fittings on a differential
pressure liquid level gauge, first open the equalization valve so you do not “peg-out”

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 the needle on the gauge.

14. Vent tank pressure down to 1-2 psi through V-19 the Vapor Recovery valve or
through V-9, the vent valve, to the atmosphere, and then close off tank. Always
maintain the 2 to 3 psi slight positive pressure to avoid back contamination.

15. Open V-5 (and V-22 for optional external on-load pump piping), the Top Fill valve
and close the bleed valve V-18, and pressurize tank to a maximum of 160 psi.
Close V-5 (and V-22 for optional on-load pump setup) and wait a few minutes before
venting.

16. Note, for every 15 psi of pressure you are adding approximately one volume of the
purge gas, effectively diluting contamination, as the pressure is vented back down to
1 to 2 psi, and the cycle is repeated until the desired purity level is achieved.

Calculating Purge Cycles

Knowing the minimum number of purge cycles needed to accomplish appropriate
purity levels before you start takes the guess work out of the process and saves
time. Figure 1 shows the equation for determining number of cycles.

Concentration of Undesired Gas Species after Number of Cycles

Cn = C0 ( Pv/ Pi )n
Where: C0 = initial concentration of the undesired gas*
C1 = concentration after one cycle
Cn = concentration after n cycles
n = number of cycles
Pi = **absolute purge gas inlet pressure
Pv = **absolute pressure to which the system is vented

* usually assumed to be 1.0, or 100%

**14.7 psi + gauge pressure
Figure 1 Source: MATHESON, Instruction Manual— Purging High Purity Gas Delivery
Systems.

EXAMPLE 1
This is an example of how this equation can be applied. Vent tank to one psi. The tank contains
one volume of undesired or unknown gas. Pressurize with natural gas to 31 psi (two times
atmospheric pressure equals two volumes). The tank now contains an approximate 33.3 percent
unknown and 66.6 percent natural gas mixture.

Next, vent to one psi and repressurize with natural gas to 31 psi. By adding another 66 percent
more methane (two more volumes) the unknown gas is diluted down by one-third again. Now
there is 1/9th as much undesired product content as before we started purging or approximately
11 percent. Vent to one psi and repressurize with methane to 31 psi a third time. The
contaminant content is approximately 1/27th of volume or 3.7 percent. Repeat a fourth time and
the natural gas impurity percent drops by one-third again to 1/81 of volume or 1.2 percent. A

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fifth purge drops the impurity level to 1/243, or approximately one half percent impurity and
99.5 percent methane.

Here is the equation for this process, which is useful as a qualitative guide.
Cn= C0 ( Pv/ Pi )n
C3 = 100 (P16/ P46**)5
C5 = 100 (0.3478)5
C5 = 100 (0.005)
C5 = 0.5% contamination or 99.5% pure methane.

EXAMPLE 2
By increasing the purge pressure to 160 psi (gauge pressure) you can achieve high purity in two
volumetric purge exchanges.

Cn= C0 ( Pv/ Pi )n
C3 = 100 (P16/ P175**)2
C5 = 100 (0.0914)2
C5 = 100 (0.0084)
C5 = 0.84% contamination or 99.16% pure methane.

17. Monitor gas purity until the required level is achieved.

18. Use the INFO button on the rear panel to increment through the automated valves
shown on the display, press the STOP button when each valve is highlighted to
close each valve. Double check that all are closed.

19. Press the SATURATE button to exit from the manual valve control screen.

20. Close V-5 (and V-22), the Top Fill Valve, V-19 the Vapor Recovery valve (if used)
and the purge vapor supply source valve and open Bleed Valve V-18.

21. If the vent stack has frost on it you are ready to fill the tank with liquid natural gas. If
the vent stack has not frosted up yet, continue purging per the instructions below
until the vent stack is frosted (approximately 45 minutes to one hour).

Tank Cool Down Purge Options

Avoid thermally shocking an ambient temperature inner vessel by the sudden addition
of cold liquid. As liquid methane expands over 600 times in volume as it changes phase
from a liquid to vapor, a catastrophic unsafe pressure rise could occur that could cause
loss of life, injury, and damage to equipment. The vent circuit and safety relief circuits
could be over-whelmed. It is also important to gradually cool down the inner vessel so

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that it thermal contracts uniformly. This avoids localized residual stresses that can
damage the tank.

Cold Vapor Cool Down in Bottom of Tank and out Top

The preferred method of cooling a cryogenic vessel is to use cold vapor first. Often, for
environmental reasons, cold vapor from the top of a liquid nitrogen tank is often used. If
cold methane vapor is used, a vapor recovery hose attached to the vapor recovery
connection should be used if the product can be reprocessed. Also preferred is to
introduce the cold vapor into the bottom of the inner vessel and use the vent valve, V-9,
to control pressure while restricting the venting vapor, or as when cyclic purging, permit
the tank pressure to rise to give time for the heat from the stainless steel inner vessel to
be transferred into the cold vapor before it is vented. In order to introduce vapor into the
bottom of the tank you must connect a hose to the 1” MNPT Drain/Liquid Sample
connection HC-5. You must also use Shore Power, as you will need the system
powered up to manually open the fireblock valve on that circuit, V-20. Follow the
instructions above to get to the manual valve control screen, to open and close V-20.

Cold Vapor Cool Down in Top Fill and out Top

If you do not have shore power to operate the control system you will have to introduce
the cold vapor into the top of the tank by connecting the cold vapor source to the
standard Top Fill connection, HC-3 and open valve V-5 to control tank pressure.
Pressurizing the tank with the cold vapor, closing the vent valve for a few minutes, then
venting it, is the most efficient means of transferring the heat from the inner vessel to
the purge/cooling vapor.

Whether introducing the cool vapor into the bottom or top of the tank, you may
alternately simply perform a continuous purge cool down. Always control the vapor
being introduced, and that escaping, to avoid over-pressuring the tank.

Purge until the vent stack frosts up, then you can carefully begin to slowly top fill,
watching the tank pressure valve and controlling the fill valve and vent valves to avoid
over-pressurization.

Least Preferred Cool Down Method is Using Liquid

This option IS NOT RECOMMENDED. The least preferred tank cool down option is the
one which requires the most attention on the part of the operator to avoid an unsafe
condition or damage to the vessel. If cool vapor is not available some companies
choose to introduce small batches of liquid through the Top Fill spray header to cool the
inner vessel down. This method does not cool down the vessel as slowly and uniformly,
to avoid thermal stresses to the inner vessel, and if not carefully monitored and
controlled the inner vessel could be over-pressurized by rapidly expanding vapor as the

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liquid flashes to gas. To cool down a vessel using liquid, first fully open the vent valve
V-9. Then only crack open the Top Fill Valve V-5 for a few seconds to little a small
quantity of liquid into the vessel, then close. The tank pressure will spike as the liquid
boils and vents. After the tank has vented down to 5 psi (maintain a positive pressure
on the tank at all times to prevent contamination), repeat this process several times,
being very careful to never allow too much product to be introduced into the tank to
keep the tank pressure low. Only once you see frost on the vent stack can you then
carefully begin to slowly top fill, watching the tank pressure valve and controlling the fill
valve and vent valves to avoid over-pressurization.

Filling the Mobile Fuel Station 16.1KTank When it is Cooled Down

The fill procedures outlined below assume that the tank has previously met warm dew
point and purity requirements and is cold with a small amount of liquid natural gas
product still in it, and meets purity requirements.

1. Set parking brake.

2. Remove chocks from holder and block wheels.

3. Walk around unit doing a visual and listening inspection of the system.

4. If dark, turn on working light (12-volt explosion-proof only will come on at front of
unit).

5. Connect static ground cable between trailer and supply source.

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 Always connect the static ground to supply source or to earth ground before
commencing product transfer operations.

6. Insert key into switch on front control panel and turn to ON position. Wait for one
minute until horn beeps once and the green Area Safe light on the front panel is
lighted, letting you know that the methane and flame detectors have booted up and
the area is safe. Do not start up the engine. You will have sufficient battery power
to the Safety System sensors.

7. Check the liquid level gauge and liquid level contents charts (for the expected
saturation pressure) and determine the approximate quantity you expect to on-load.

8. Look at the pressure gauges on the trailer tank and on the supply tank. In order to
dispense product the vehicle tank pressure must be 25 to 50 psi lower than the
pump’s discharge pressure (or than the supply tank’s pressure if it has no pump).
Follow your company’s procedures when venting a tank. Methane is reported to be
a greenhouse gas 23 times worse than carbon-dioxide. Venting to the atmosphere
is not recommended.

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9. Connect fill hose to supply source and to trailer Top Fill connection, HC-3 (if you
have to fill from an LNG fuel station pump connect to HC-6 fill receptacle).

10. Connect vapor recovery hose to HC-2, if you are able to recover any vapor instead
of venting it. Normally you should not have to vent a cold tank, as the cold liquid you
are filling it with will rain down through the warm vapor space, collapsing tank
pressure. If you do intend on recovering vapor, to avoid contamination to the supply
source, purge the hose on the return side before opening V-19, the Vapor Recovery
valve.

11. Open V-18 bleed valve.

12. Crack open supply source liquid valve and purge through the hose to eliminate any
humid air contamination for one minute.

13. Open V-5 (and V-22 for external on-load pump setup), the Top Fill valve and close
the bleed valve V-18.

14. Slowly open the supply source liquid valve and monitor tank pressure. Choke down
the supply flow of product into the trailer, or choke V-5, if the pressure starts to rise
too much. Also, vent pressure back into the supply through the vapor recovery
hose, or open Vent valve V-9 to vent to the atmosphere (not recommended as un-
combusted methane is a greenhouse gas). If filling using a pump, control pump
discharge pressure and tank pressure as required.

15. Crack open the Full Trycock Valve, V-13, and check the liquid level chart to make
yourself aware of the approximate water column liquid level you expect the tank to
fill at (will vary depending upon the saturation temperature of the liquid, and amount
in the tank, and that you are filling with). Open the trycock a little wider as you get
close to the full level as indicated by the liquid level gauge. Also, you may fill by
weight if filling using scales; but still also use the full trycock to make sure you do not
over-fill past the DOT limit. There must be sufficient head space for liquid expansion
as it warms and/or as it is intentionally saturated with heat.

16. Connect analyzer to connection HC-5 and open V-1, Liquid Sample / Drain valve if
verifying purity. You will also have to use the rear display to manually open the PB
Fire block valve, V-20, to allow liquid to exit the tank (do not open the PB Valve, V-4
or you will build pressure while you are filling). Press and hold down both the
START and STOP buttons to enter this mode. Use the INFO button to increment to
V-20. Press START to open the valve.

17. When the full liquid level or weight is achieved, (see Liquid Level Chart) and for sure
when liquid spits from the full trycock valve, close the liquid supply source valve. DO

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 NOT OVER-FILL.

18. Close the Top Fill valve, V-5 (and V-22) and open the drain valve V-18.

19. Close the Vapor Recovery hose valve if used, V-19, and Recovery side valve, and
carefully depressurize hose, remove and stow.

20. Carefully remove the fill hose. Do not stand directly behind it while loosening and
removing. Set one end of the hose down on the ground to drain out any residual
product. Then stow hose.

21. Replace the pressure caps on the Top Fill and Vapor Recovery connections.

22. Press STOP to close the PB Fire Block V-20, and close V-1, Liquid Sample / Drain,
remove sample analyzer tubing, and replace plug with vented hole drilled in it.
Press SATURATE to exit the manual valve control screen.

23. Turn off front control panel, or perform a Saturation operation to saturate the new
product with heat to the required pressure/temp, as per described in the Saturation
Operation section of this manual.

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Filling Refueler Using Optional External On-Load Pump

If your unit is equipped with the optional external On-load pumping system you may use
the pump to fill the mobile refueler. More information on both the submerged and
external pumps is included in the appendix.

1. Set parking brake.

2. Remove chocks from holder and block wheels.

3. Walk around unit doing a visual and listening inspection of the system.

4. If dark, turn on working light (12-volt explosion-proof only will come on at front of
unit).

5. Connect a static ground from the supply source to the mobile refueler (or vise-
versa).

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 62

Always connect the static ground to receiving vehicle before commencing product
transfer operations.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 63

 6. Connect two hoses from the supply source to the mobile refueler HC-3 Top Fill
Connection and HC-9 On-Load Pump Inlet connection. The recirculation hose
needs to dump back into the top of the supply tank. As the pump is cooled down
the vapor will return to the supply tank. When the pump is started and catches
prime it will recirculate back into the top of the supply tank until you are ready to
speed the pump up and divert the flow into the mobile refueler Top Fill.

Optional External On-Load Pump connection and valves

7. Look at the pressure gauge on the nitrogen pump seal purge bottle to assure
there is sufficient gas, then open the valve on the nitrogen bottle. The external
on-load pump seal is purged with a slight positive pressure of dry nitrogen gas to
keep out ice crystals to extend the life of the pump seal and for safety. The
pressure regulator on the bottle performs a first stage pressure reduction role,
and a high pressure restrictor valve downstream right before the pump seal
drops the pressure to less than 1 psi and restricts the flow into the seal.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 64

 8. Nitrogen gas bottle is secured and is used to purge the external on-load pump
seal with a slight positive pressure purge.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 65

 Blue hose supplies slight positive pressure nitrogen purge to the external on-load
pump seal.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 66

 Restrictor valve drops the pressure from the regulated nitrogen gas bottle to less
than one psi and only a slight positive pressure flow to the external on-load pump
seal.

9. Open the delivery valve on the supply source and open V-23, the On-Load Pump
Inlet Bleed valve and purge for several seconds through the pump, then close

10. Open the On-Load Pump Top Fill valve V-21 and the On-Load Pump
Recirculation valve V-22.

11. Open the bleed valve at the recirculation hose connection on the supply for
several seconds then close.

12. Open the valve on the supply source recirculation circuit that will permit flow back
into the top of the supply source tank. The pump can now cool down.

Note, that due to low and high places caused by the use of hoses gas can be
trapped, preventing a natural gravity flow recirculation of liquid into the pump and
vapor back into the supply source as the pumping circuit is cooled down. It is
highly likely therefore that the operator may need to close the return valve on the
supply source and open the bleed valve where the return/recirculation hose
connects to the supply source. The operator may also need to open bleed valve

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 67

 V-18 on the refueler to permit the vapor to vent to the atmosphere to accomplish
the pump cool down.

13. Cool the pump down for a minimum of 12 minutes. Just because a pump is
frosted does not mean that it is cold to liquid temperature. Starting a warm pump
means that liquid is boiling inside the pump to cause cavitation which is
detrimental to the pump’s seal.

14. Open the pressure builder on the supply source and build 5 to 10 psi subcool
pressure on the supply liquid.

15. While the pump is cooling down, start the unit and turn the pump selector switch
to position #2, to select the external pump.

Turn the black pump selector switch (top left) to position #2 to select the external pump
(submerged dispense pump and external on-load pump labels not shown in this photo).

16. Make sure the vapor return valve on the supply vessel is open (if you have been
using the bleed valve it may be closed.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 68

 17. Make sure the external pump speed control potentiometer knob on the rear
control panel is turned all the way counter-clockwise (if it is not a message will
appear on the rear display to remind you to turn it counter-clockwise.

18. Press the START button on the rear control panel to start the external pump.

19. Turn the potentiometer speed control knob on the rear panel to ¼ to ½ speed to
catch prime.

When in the external on-load pump mode the rear display screen assists the
operator on what to do. This is not a fully automated mode; the operator is
responsible for many operational details.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 69

 The external on-load pump cannot be started unless the potentiometer speed
control knob is in the fully counter-clockwise position.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 70

 This display will pop up on the rear control panel if the pump selector switch on
the front control panel is left in the off or 0 position.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 71

 Press the green START button to start the external On-Load Pump (when front
selector switch is set to position #2 – external on-load pump). Then turn the
potentiometer knob clock-wise to increase the external pump speed. Press
STOP FILL to stop the pump.

20. Immediately slowly start closing V-22, the On-Load Pump Recirculation Valve
while watching the pump discharge pressure gauge, P-2. When the pressure
gauge jumps up you have caught prime and must continue closing down the
valve a little more to create back pressure on the pump so that it sounds good
and is not cavitating. If you keep choking down the Recirculating valve and do
not see the discharge pressure increasing quickly open it back up just a little.
You want to control the back pressure to achieve almost, but not quite, the
maximum discharge pressure. Do not close the valve too far so that you dead-
head the pump.

If you experience problems catching prime keep bleed valve V-18 open and the
bleed valve on the recirculation vapor return side on the supply vessel and then
start the pump. As you are “pressure transferring” through the pump into the

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 72

 atmosphere when you start it, the impellor will be flooded and you will then be
able to catch prime. Then immediately close the bleed valve and adjust the
recirculation valve to achieve the required back pressure and so the pump
“sounds” good.

21. Slowly turn the pump speed control potentiometer knob clock-wise to increase
the pump speed to achieve the desired pump discharge pressure. Pump
discharge pressure equals supply tank pressure plus the capability of the pump
at full speed. Increasing the supply tank pressure will add to the discharge
pressure.

22. Make sure the pump discharge pressure is 25 to 50 psi higher than the mobile
refueler tank pressure to transfer product. You may have to vent the mobile
refueler tank pressure down via valve V-9.

23. Note the anticipated full liquid level on the contents liquid level gauge, watch the
scales if filling by weight, and partially open the Full Trycock valve V-13.

24. Slowly partially open the Top Fill valve V-5 while at the same time slowly closing
the On-Load Pump Recirculation valve V-22 to start top filling the mobile unit.
Keep V-5 choked back as needed to maintain the pump discharge pressure
needed and to keep the necessary back pressure on the pump to keep it from
cavitating (in the event the mobile refueler pressure is low and does not provide
sufficient back pressure). You can open the Top Fill valve V-5 to increase the
flow rate as long as you maintain the pump pressure 25 to 50 psi higher than the
receiving pressure, and as long as the pump sounds good (cavatition does not
sound good).

25. Monitor and control the discharge pressure, supply tank pressure, mobile tank
pressure, liquid level gauge, and full trycock throughout the on-load operation.

26. Note the anticipated full liquid level on the contents liquid level gauge and the full
level indicated on the liquid level contents charts, watch the scales if filling by
weight, and partially open the Full Trycock valve V-13.

27. When liquid spits from the Full Trycock valve V-13 (or when you achieve the
desired legal over-the-road weight if sooner), press the STOP button. DO NOT
OVER-FILL.

28. Turn the potentiometer speed control knob all the way counter –clockwise so it
will be in the correct position for the next fill.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 73

 29. Close the supply source liquid valve and the supply source recirculation/vapor
return valve.

30. Close the Top Fill Valve V-5 and On-Load Pump Top Fill valve V-21.

31. Close the Full Trycock valve V-13.

32. Close Vent valve V-9 if open.

33. Open the On-Load Pump Inlet Bleed V-23 and the Fill Line Bleed Valve V-18 and
the bleed valve on the supply source to depressurize and drain both transfer
hoses. Then close.

34. Close the On-Load Pump Recirculation Valve V-22.

35. Carefully remove both hoses. Be careful for liquid still in the hose in the low
sections, even if all pressure is bleed off. Stow hoses.

36. Turn off the pump seal purge gas high pressure nitrogen bottle.

37. Remove and stow the static ground cable.

38. Remove wheel chock blocks.

Saturation Operation
Saturation Summary
Many LNG fueled vehicles do not have a fuel pump and thus require that the LNG be
supplied in an uninterrupted manner at a pressure specified by the engine
manufacturer. As artificial head pressure generated with a pressure building unit would
be knocked down as the colder liquid sloshed up into the ullage space as the vehicle
travels over the road, it is necessary to provide fuel to the engine that is already
“saturated” with heat to temperature/pressures required by the engine manufacturer.
This means heat is added to the liquid so that it achieves the desired pressure, and if
even one more BTU of heat is added the liquid would boil.

Most product is loaded at a relatively low saturation pressure (cold liquid). Heat is
added to the liquid until it is saturated with enough heat to cause the liquid to boil when
a target pressure (temperature) is attained. The mobile refueling system controller then
is programmed to raise the saturation temperature/pressure of the liquid to the pre-
programmed value. This value can be programmed via a password by CVA or a
customer appointed and trained representative. Please contact CVA if you need to
change the Saturation Pressure and we can easily talk you through it over the phone.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 74

As there are other parameters that could also be inadvertently changed we do not wish
to publish that password or instructions.

Liquid is pumped from the tank through the vertical aluminum star-finned saturation
vaporizer located in front of the tank where it picks up ambient heat. The two-phase
product then is pumped up into the bottom of the tank through a sparger (bottom spray
header) where the warmed liquid and vapor rise up through the cold liquid. If the tank
pressure rises too high during the operation the valves will automatically actuate to
temporarily stop pumping through the saturation vaporizer and instead recirculate so
that the liquid inside the tank rains down through the head space lowering the tank
pressure. When the pressure is back in range the system will automatically continue
pumping the liquid to the vaporizer and back into the tank. When the RTD senses that
the saturation temperature has been achieved, the system will recirculate for a few
minutes to mix up the liquid to eliminate any cold or warm pockets of product.

An aluminum star-finned ambient saturation vaporizer is located under the tank.

Thus, after filling the refueler, the operator often needs to perform a saturation
operation. When in the dispense mode, after the pump catches prime and is
recirculating, the controller will monitor the temperature of the product and perform a
check to see if the product is saturated to the programmed level. If not, the operator will
be alerted and he will have to perform a saturation operation before he can dispense
product.

To perform a saturation operation:

1. Press the green START button to catch prime or press the SATURATE button.

2. When prompted (after the Target Sub Cool Pressure has been attained and all
other conditions are OK) press the SATURATE button to begin the saturation

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 75

 operation. The pump will start and ramp up to a programmed speed. Product
will be pumped from the rear of the trailer to the front and through the saturation
vaporizer. The two-phase flow (liquid and vapor) will return to the back of the
trailer and enter a sparger along the bottom inside of the tank. The sparger is a
spray header – a pipe with holes drilled in it down its length. The warmed liquid
and vapor raises up through the colder liquid in the tank. The controller monitors
the temperature of the liquid exiting the pump and the tank pressure. Should the
tank pressure ever rise above a pre-set amount over the measured temperature
of the liquid, the system will go into recirculation mode and not pump liquid
through the saturation vaporizer until the tank pressure has dropped down to
within acceptable limits. Also, once the system thinks it has achieved the target
Saturation temperature/pressure, it will recirculate for a few minutes before
shutting down to “mix” any warm and cold liquid within the tank. The saturation
operation may take up to two hours, depending upon the starting and target
saturation pressures. The saturation pressure is displayed on the rear display
once the liquid is recirculating.

3. The saturation operation will automatically stop when done, or can be manually
stopped by pressing the red STOP button. The Saturation Cycle has a (2) two
hour maximum time limit built in.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 76

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 77
Daily Inspections and Maintenance
1. Perform standard DOT operator inspection of vehicle and delivery system.

2. Open the two vent stack drain valve (1/4” needle valves located at the rear control
area) to drain any moisture from the vent stacks.

3. Pull the cables on the air tanks drain plugs to drain any water from the air tanks.
Note: The air tanks are located under the front of the trailer.

4. Inspect piping and valves for visible signs of leaks, e.g. frost.

5. Inspect nozzles and receptacles.

6. Inspect hoses.

7. Check trailer tire air pressure and tire condition.

Drain valves on vent stacks to drain melted frosted from inside stacks.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 78

Weekly (or more often if needed) Inspections and Maintenance

1. Inspect manway on top of tank for leaks. Note there are inner and outer vessel
manways. A lift plate is designed into the outer lift plate to relief pressure should
there ever be a leak on the seal of the inner manway.

2. Leak check rear piping, saturation piping from rear to front saturation vaporizer, the
pump’s electrical pass-through at the front.

3. Check tension on drive belt on air compressor, alignment and check for wear.

4. Check static drag strap and adjust length as needed due to wear so that it stays in
contact with the ground.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 79

5. Check air dryer is functioning properly and maintain per manufacturer’s manual
guidelines.

6. Test E-Stop buttons.

7. Inspect fire extinguishers.

8. Inspect condition of rubber bladders on air actuated valves.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 80

Monthly to Quarterly Inspections and Maintenance as Required
1. Check air dryer is operating correctly.

2. Test methane detectors every 90 days using a calibrated bottle of methane gas
following manufacturer’s guidelines. (see guidelines in appendices)

3. Replace seal in fill nozzle.

As Required Maintenance

1. Clean battery posts and cables.

2. Replace burnt out lighting elements.

3. Leak check piping and valves using leak detection solution (open valves
manually using the valve control electronic display screen). Leak check
manways.

4. Leak check the two in-line electrical pass-through fittings that allow the electrical
leads form the submerged pump inside the tank to exit the pressure vessel.

Annual or as Required Inspections and Maintenance

1. Prep and touch up paint where needed.

2. Calibrate flow meter system.

3. Check calibration on pressure gauges and Liquid Level gauge, differential pressure
transducer, pressure transducers, pressure switches, RTD.

4. Take to DOT registered facility for annual and multi-year inspections as required
(visual, pressure, relief valves, etc.).

5. Measure vacuum only if you have reason to believe you have a problem with the
vacuum, i.e. rising tank pressure and condensation on tank when there is no
condensation on other metal surfaces.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 81

 Evacuation Port. Do not break the wire seal or your vacuum warranty will be
voided.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 82

 To measure vacuum use a DV6 meter. Open Hoke “peanut” valve, wait 5 minutes,
then connect vacuum meter. Always close the Hoke valve after you have read the
vacuum level.

Replacing the submerged pump

1. Install hose on 1” Drain connection HC-5 and connect hose to storage tank.

2. Vent pressure in storage tank to as low as possible, but at minimum it must be

maintained at least 25 psi below the trailer pressure.

NOTE: there is no line relief valve on this drain connection. NEVER CLOSE
THE INLET VALVE ON THE STORAGE TANK AND THE DRAIN VALVE, V-1,
TO TRAP LIQUID IN THE HOSE. AS IT WARMS IT WILL EXPAND MANY
TIMES IN VOLUME AND EXPLODE. YOU SHOULD HAVE A LINE RELIEF
ON THE INLET SIDE OF THE STORAGE TANK TO PROTECT THE DRAIN
HOSE.

3. To build pressure the system must be running and powered up. Press and hold
down the START and STOP buttons to bring up a screen on the rear Panel View
display to control operation of the valves via button selection. Use the INFO

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 83

 button to increment or scroll through the list of valves. Press START to open a
valve. Press STOP to close a valve. Open the PB Fire Block valve V-20 and the
Pressure Build Valve V-4. Closely monitor tank while draining the tank of product
to keep the pressure well below the 175 psi maximum working pressure of the
tank. Close V-4, the PB inlet valve if needed, and vent the receiving storage
vessel as required.

4. Open V-1and then open the bleed on the receiving storage side to purge the
hose, then close the bleed/purge valve.

5. Open the inlet on the storage tank side to begin transferring product.

6. Use pressure to transfer off and drain all liquid from the tank, and then continue
to vent down pressure to 1 psi. You can terminate the operation and close the
PB Fire Block valve, V-20 and the PB valve, V-4, close the valve on the receiving
vessel, vent the hose and carefully remove it. DO NOT LEAVE THE HOSE
CONNECTED – USE A LINE RELIEF VALVE ON THE HOSE IF THERE IS NOT
ONE ON THE STORAGE TANK SIDE OF THE CONNECTION.

7. Press the SATURATE button to exit the manual valve control screen.

8. Allow the tank to warm for 3 or 4 days, or purge with ambient or warm nitrogen to
expedite the process – but it will still take several hours to warm the inner vessel,

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 84

 i.e. a day or more (never use any purge gas hotter than 250F to avoid damage to
valves). You must ensure that venting purge/warming gas is back to ambient
temperature, indicating that the inner vessel is also at ambient temperature,
before opening the tank to prevent condensation forming on the inside surfaces
of the vessel. If you warmed the inner vessel with nitrogen, you must then purge
with oil-free dry shop air. Monitor the exiting gas until the vessel is safely purged
of methane.

WARNING: Follow all company lock out/tag out procedures and confined
entry procedures.

9. Open the vent valve and vent tank pressure to atmosphere. Carefully remove
out manway lid and insulation materials in the manway annulus. Double check
the vent valve is open and there is no pressure on the tank. Carefully remove
the inner vessel manway. Note an over-head crane is required to lift the heavy
lid.

10. Use a string to lower a thermometer and a portable gas analyzer down into the
tank to ensure that it is both warm and safe for entry. Never enter a tank
without following all confined space entry procedures.

11. Use appropriate ladder, clean safe lighting, and wear a clean room bunny suit,
booties, and hair net when entering the inner vessel.

12. Mark pump motor leads, cut crimps, remove pump vortex breaker, unbolt
discharge flange, and unbolt pump.

13. Slide pump along bottom of tank and through hole in bottom of slosh baffles. Lift
old pump out of tank, through the manway using an over-head crane.

14. Keep new pump and motor in its sealed plastic wrapper until you are ready to
lower it into tank. Do not leave it out uncovered or dust particles will eventually
ruin the bearings. Lower new pump into tank and drag to front of tank and
remount. Make sure the pump discharge flange properly aligns in a relaxed
state. The discharge flex section is for vibration, not for mis-alignment. Inspect
and replace if needed. Make sure all flange bolts and mounting bolts have double
nuts and that they are tight (you do not want loose nuts and bolts in the bottom of
the tank).

15. Crimp the power leads back to the same leads (otherwise the pump may run
backwards and you will have to swap two leads later at the VFD). Cover the
crimp fittings and shrink using only PURE TEFLON heat shrink only. Other
types of black heat shrink that have some Teflon in them will nevertheless

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 85

 embrittle and break and contaminate the inner vessel.

IMPORTANT: Use pure clear / white Teflon only heat shrink to cover the wire
connection crimp connectors to contain any crimp cover plastic particles that
could embrittle and break away.

IMPORTANT: Do not use black tape or ziplock ties in the inner vessel – they
cannot withstand the cold and will break up and contaminate the system and
ruin the pump, valves, and customer equipment.
IMPORTANT:

Do not test run submerged pump dry!

16. It is recommended that you use a Megger to test the leads to the motor (or at
minimum check that you do not have continuity to ground).

17. Carefully clean the inner vessel and the inner surface of the manway lid using
industry acceptable oxygen cleaning procedures and proper cleanliness
inspection procedures.

18. Install new manway gasket (contact CVA for gaskets) and perform SEVERAL
crisscross and re-crisscross tightening sequences. Torque the inner vessel
manway to 175 foot-pounds.

19. Pressurize with vapor to 150 psi and leak check the manway gasket.

20. Re-install the insulation in the space between the inner and outer vessel.

21. Inspect the O-ring on the outer vessel lift plate installed on the manway lid (this
prevents a leak from the inner vessel lid from over-pressurizing the outer vessel
lid). Clean and apply a thin film of grease if needed.

22. Apply a new gasket on the outer manway (contact CVA) and perform SEVERAL
crisscrosses and re-crisscross tightening sequences. Torque the outer vessel
manway to 70 foot-pounds.

23. Follow procedures to gradually and uniformly cool down the inner vessel, purge,
and fill with product.

24. Start the system up and start up. Watch the discharge pressure gauge and be
ready to stop if the pump doesn’t catch prime. If it does not catch prime, it is
possible that you have motor leads reversed. You can swap any two of the three
legs at the VFD. NOTE you may still see up to 25 PSI discharge pressure with
the motor running backwards. If you do not achieve normal recirculation

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 86

 pressure STOP immediately and swap two leads.

25. Contact InoxCVA for the password and instruction on how to reset the pump run
time to zero hours and the total delivery to 0.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 87

SPARE PARTS

As the automated refueling system was designed for ease of use and troubleshooting it
is nevertheless a complex system. Components were selected for durability, but as this
is an over-the-road system, components may not last as long as they would on a
stationary system. Major components were selected that could be easily purchased
locally, i.e. the PLC, Panel View, VFD, and many electronic components were
purchased from Allen-Bradley (and are not listed below). However, some components
may not be available off the shelf. The user should review the following list to determine
what spare parts to keep on hand. The CVA Part Number is listed in the left column.
Contact CVA at 281-385-1204 for spare parts. Note, CVA may not keep all of these
components in stock – lead times may be associated with some components.

CVA PN# Name Component Description

ELE407 PRESSURE TAMPER-RESISTANT NON-ADJ PRESSURE
SWITCH SWITCH 1/8" NPT MALE @ 80 PSI
ELE408 PRESSURE TAMPER-RESISTANT NON-ADJ PRESSURE
SWITCH SWITCH 1/8" NPT MALE @ 100 PSI
ELE382 PRESSURE DIFFERENTIAL PRESSURE TRANSMITTER

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 88

 TRANSMITTER
0-10" TO 0-400" H2O / 0-25 TO 0-1000 MBAR
316SS PROCESS HEAD, 316SS VENT, 316LSS
BAR
24VDC - 4-20MA SIGNAL
DC 200SILICONE FILL FLUID
1/2"MNPT W/ ADAPTER (ON 1/4" MNPT HEAD)
PROCESS HEAD
HART 5X PROTOCOL COMPATIBLE
ELECTRONICS
SMART METER
316SS ADAPTER FLANGE - 1/2" MNPT WITH
CS BOLTS
ANGLE MOUNTING BRACKET - CARBON
STEEL
FACTORY MUTUAL APPROVAL
CLASS I, DIVISION I

P/N: STD924-E1H-00000-1C,DE,MB,SM
ELE437 RTD ELEMENT R1T185L483-004-00-8HN22
REPLACEMENT RTD ELEMENT

1/2" X 1/2" 316SS HEX FITTING W/ 4"

INSERTION PROBE

ELE550 SOLENOID ASCO REDHAT SOLENOID VALVE, 12VDC,

VALVE 1/4"
ELE375 SOLENOID ASCO REDHAT SOLENOID VALVE, 24VDC,
VALVE 1/8"
KITCRYO020 CENTRIFUGAL AC/TC-34 1" X 2" X 6"-2S CENTRIFUGAL
PUMP CRYOGENIC PUMP
ALL BRONZE CONSTRUCTION, 2-STAGE,
SEALLESS, SUBMERGED PUMP ASSEMBLY
RATED FOR 40 GALLONS PER MINUTE AT 820
FT OF DIFFERENTIAL HEAD IN LIQUID
NATURAL GAS SERVICE @ 6,000 RPM'S
IMPELLER DIAMETER IS SIX (6) INCHES
COMPLETE WITH INTEGRAL 15.0 HP, 460 V, 3-
PHASE, 60 TO 120 HZ, FULLY SUBMERSIBLE,
VARIABLE SPEED MOTOR
PUMP & MOTOR CAN BE FITTED INTO
STAINLESS STEEL VACUUM-JACKETED

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 89

 PRESSURE VESSEL RATED AT 275 PSI
COMPLETE WITH DUAL ELECTRICAL
JUNTION BOX AND STAINLESS STEEL RELIEF
VALVE PER NFPA REQUIREMENTS FOR
LIQUID NATURAL GAS SERVICE
SUMPS ARE ASME CODE, RATED AT 200
PSIG
NPSHR = 4.4 FT; ACD P/N 54095
(SUMP IS NOT PART OF THIS ASSEMBLY)

THIS MODEL DESIGNED IN ACCORDANCE

WITH NFPA 70 ELECTRICAL STANDARDS
(NATIONAL FIRE PROTECTION
ASSOCIATION) SECTION 501-8 AS
EXPLAINED IN THE ELECTRICAL HAND
BOOK, ITEM FOUR (4), FOR LNG SERVICE.
THE MOTOR IS DESIGNED TO BE FULLY
FLOODED IN PRODUCT, THEREBY TOTALLY
DISPLACING OXYGEN ASSURING A SAFE
OPERATION CONDITION

ELE605 TRANSFORMER 6KVA 3 PHASE 480V DELTA-WYE

TRANSFORMER

ELE450 ROLLER ARM ADJUSTABLE ROLLER ARM FOR LIMIT

SWITCH

ELE448 LIGHT GUARD EXPLOSION PROOF GUARD FOR 12 VDC AND

120 VAC

KITCRYO032 CENTRIFUGAL AC/TC-34 KA 1” X 2” X 6” – 2S, CENTRIFUGAL

CRYOPUMP CRYOGENIC PUMP, 2-STAGE, SEALLESS,
SUBMERGED PUMP ASSEMBLY; RATED FOR
130 GALLONS PER MINUTE AT 800 FT OF
DIFFERENTIAL HEAD IN LIQUID NATURAL
GAS SERVICE @ 7200 RPM.

CRYOPMP001 CENTRIFUGAL AC/TC-30 1.5 X 2.5 X 10 CENTRIFUGAL PUMP

CRYOPUMP BRONZE CENTRIFUGAL TRUCK MOUNTED
PUMP ASSEMBLY. PUMP IS COMPLETE WITH

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 90

 LOW NPSH INDUCED SUCTION INLET AND
MECHANICAL SEAL WITH INTERMEDIATE
GN2 PURGE KIT INSTALLED. PUMP IS RATED
FOR 200 GPM AT 652FT DIFFERENTIAL HEAD
IN LNG SERVICE @ 4281 RPM. UNIT IS
COMPLETE WITH INTEGRALL;Y MOUNTED
30HP, 230V/460V, 3PH, 60-120 HZ, TEFC
EXPLOSION PROOF INVERTER DUTY MOTOR

COMP0101 AIR COMPRESSED AIR SYSTEMS BASE

COMPRESSOR MOUNTED AIR COMPRESSOR; 2HP TEFC
DRIVE MOTOR, GS12 PUMP, 460/3/60; 6.5
CFM @ 125 PSIG, NEMA 4 ENCLOSURE

ELE583 DC-DC VOLTAGE DC-DC VOLTAGE CONVERTER; INPUT: 11-15

CONVERTER VDC @ 15 AMPS; OUTPUT: 24 VDC @ 5.5/5
AMP PEAK/CONTINUOUS; DEIMENSIONS:
7.9"L X 6"W X 2.4"H, 2.5 LBS.; INCLUDES
EXTRA WIDE TEMERATURE OPTION

ELE364 METHANE INTELLIGENT SENSOR FOR COMBUSTIBLE

DETECTOR GAS DETECTION 4-20Ma OUTPUT CLASS I,
DIVISION I, GROUPS B, C & D

ELE441 METHANE SLASH GUARD ASSEMBLY FOR METHANE

DETECTOR DETECTOR
SPLASH GUARD

ELE365 FLAME FLAME DETECTOR 4-20Ma OUTPUT

DETECTOR CONTINUOUS OPTICAL PATH THREE SPDT
PROGRAMMABLE RELAY OUTPUTS

ELE489 FLAME ALUMINUM BRACKET ASSEMBLY FOR FLAME

DETECTOR DETECTOR
MOUNTING
BRACKET
ELE462 SELECTOR 5 POLE, 2 POSITION + CENTER OFF A1
SWITCH MOUNT W/OPTION 69 (TERMINAL COVERS:
SHORE - OFF - GEN)

CONNECTOR 600V/347Y 3PH CONNECTOR

ELE556

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 91

ELE557 INLET 600V/347Y 3PH MALE INLET

ELE571 CLOSURE CAP CAP FOR MALE INLET

ELE572 INLET BACK BOX INLET BACK BOX FOR MALE INLET

ELE449 LIMIT SWITCH 24 VOLT LIMIT SWITCH

ELE395 EX-PROOF EXPLOSION PROOF WARNING SIREN 24VDC

SIREN 1.2 AMPS (OPERATING CURRENT) DECIBELS
@ 10': 99 DECIBELS @ 1M: 110

7955454 AIR GUN AIR NOZZLE

COILED AIR HOSE, FLEXIBLE, HOSE INSIDE

TOOL132 AIR HOSE DIA 1/4 IN, USABLE LENGTH 12 FT, HOSE
LENGTH 15 FT, NPT SIZE 1/4 IN, MALE RIGID
X MALE SWIVEL CONNECTORS, HOSE
OUTSIDE DIA 0.38 IN, TRANSPARENT BLUE
COLOR, MAX PRESSURE 120 PSI, PIGTAIL
LENGTH 8 AND 16 IN, TEMP RANGE -104 TO
158 F, TUBE MATERIAL POLYURETHANE,
COVER MATERIAL POLYURETHANE, SAFETY
FACTOR 3:1 @ 75 F, OIL, GREASE AND
MOISTURE RESISTANT

AIRTNK02 ALUMINUM AIR ALUMINUM AIR TANK ABS TANK 8" DIAMETER
TANK

CAL002 CALIBRATOR PORTABLE PURGE CALIBRATOR BOTTLE

50% METHANE

CAL003 CYLINDER REPLACEMENT PURGE CALIBRATOR

CYLINDER

FUSELINK01 FUSABLE LINK FUSABLE LINK; FIRECHEK FC4

MELTING POINT 74* CELSIUS, 165*
FARENHEIT
HOS147 LNG SMART 1"ID X 15'OAL, STAINLESS STEEL, SMART
HOSE HOSE
CLOSE PITCH CORRUGATED 304 STAINLESS
INNER CORE
HEAVY DUTY FNPT END FITTINGS EACH END

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 92

 18" ARMOR CUFF CASING EACH END
LNG SERVICE
SERVICE TEMP: -260*F
TEMP RANGE: -320*F TO 1500*F
WORKING PRESSURE: 450 PSI
MAXIMUM PRESSURE: 560 PSI

P/N M03-008-14-0180-B-00-00
HOS148 LNG SMART 1/2"ID X 15'OAL, STAINLESS STEEL, SMART
HOSE HOSE
CLOSE PITCH CORRUGATED 304 STAINLESS
INNER CORE
HEAVY DUTY FNPT END FITTINGS EACH END
18" ARMOR CUFF CASING EACH END
LNG SERVICE

P/N M09-004-0180-B-00-00
AIRDRYER02 PUREST AIR HALDEX, PUREST AIR DRYER
DRYER 24-VOLT
7956041 REGULATOR Tamper- Resistant Air Regulator 1/2" Pipe Size,
60 Max SCFM, 0 to 125 PSI Range
7956042 MOUNTING MOUNTING BRACKET FOR REGULATOR
BRACKET
7956043 GAUGE 0-125 PSI GAUGE

ELE381 TRANSDUCER EXPLOSION PROOF PRESSURE

TRANSMITTER
MODEL: E-10
PRESSURE: 0-500 PSI
INPUT: 10-30 VDC
OUTPUT: 4-20 mA
VERSION: CABLE
CONNECTION: 1/2"MNPT
CABLE LENGTH: 6'
ELE334 EX-PROOF LIGHT EXPLOSION PROOF LED STEADY BURN
STROBE LIGHT; 12-36 VOLTS DC - 141
CANDELA - WITH CEILING MOUNT; CLASS 1,
DIV 1

MODEL# EPSL-80-141-VDC-CLG-WHT
ELE460 LED LIGHT EXPLOSION PROOF LED STEADY BURN
STROBE LIGHT - 120-240 VOLTS AC - 141

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 93

 CANDELA - WITH CEILING MOUNT; CLASS 1,
DIV 1

MODEL: EPSL-80-141-VAC-CGA-WHT
GRNDBRD001 GROUNDING FLEXIBLE BRAIDED GROUNDING CABLE LUG
BRAID TO LUG, 9" CENTER TO CENTER, 4 GAUGE
ELE378 EX PROOF EXPLOSION PROOF STROBE LIGHT
STROBE LIGHT COLOR: RED
VOLTAGE: 24V
FREQUENCY: 80 FLASHES PER MINUTE
CERTIFICATION: CLASS I, DIVISION I
70000483 GASKET-FOR GASKET-FOR LNG 3" MALE CGA FITTING
LNG 3" MALE
CGA FITTING
COMP009 FAN BELT REPLACEMENT FAN BELT FOR 2HP 20 GAL.
AIR COMPRESSOR (CVA P/N COMP007)
NOZZLE007 NOZZLE REPAIR BASIC NOZZLE REPAIR KIT, INCLUDES:
KIT
SPRING ENERGIZED SEAL
SEAL RETAINER
EXTERNAL BOWED RETAINING RING
NOZZLE008 NOZZLE REPAIR PREMIUM NOZZLE REPAIR KIT, INCLUDES:
KIT SEAL DISC
BRONZE BEARINGS
SPRING ENERGIZED SEAL
SEAL RETAINER
BRASS FLAT WASHERS
POPPET SLEEVES
RETAINING RING
EXTERNAL BOWED RETAINING RINGS

TROUBLE SHOOTING
The refueling system is designed with many smart features to assist with not only the
operation of, but also with trouble shooting of electronic circuits and equipment and for
other piping and system circuits. The Programmable Logic Controller (PLC) / Panel
View will alert you to many issues, as will the Variable Frequency Drive (VFD). Some
problems may have to be intuitively diagnosed with the assistance of CVA. Always note
down the operational conditions just prior to, and those experienced during a problem,
including any messages on the PLC or VFD in the front enclosure and the Panel View
display in the rear enclosure, before contacting CVA for assistance. A few basic issues
are diagnosed below.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 94

 I turned the key on and the green 24 Volt DC Power light did not come on.

Check the four E-Stop buttons to see if one is depressed. The red overhead
alarm light should be on if one is pressed.

Check to make sure the battery is not dead.

Check fuse in 12 to 24 bolt power supply inside front enclosure and also check
the power supply is working.

System shuts down with a LOW FLOW or HIGH DIFFERENTIAL PRESSURE

message

Read display screen for additional information. Also press INFO button. Check
pressure in the receiving vessel – it may be too high and needs venting.
Connect vent hose and vent and briefly open diverter valve DV-1 to purge hose
to atmosphere, then vent vehicle tank into refueler tank. The vehicle tank should
be 25 to 50 psi lower than the maximum pump discharge pressure. Note that
when you fill with a warm hose that you will brief add pressure to the vehicle fuel
tank due to the warm hose flashing liquid to vapor until it cools.

Not building system air pressure or air pressure timing out on rear display.

Restart system. Check air compressor on road side front fender. Is it running?
Is the fan belt on the air compressor broken? Is it properly tensioned?

Does the pressure gauge show there is pressure in the air tank? If so check the
80 and 100 psi pressure switches located beside the air dryer.

If it is winter and you have air pressure in the air compressor pull the water drain
cable. Follow the air to the back to see if you have ice in an air line.

Rear display says I have air pressure but the valves are not actuating.

Can you get air out of the shop air hose at the back of the trailer? If not, check
for an ice blockage in an airline if it is winter.

Check to make sure the FireChek pneumatic fusible link (in-line in the air line
right before the solenoid that opens to let air actuate the valve) is not tripped.
Rest by twisting knurled ring ¼ turn

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 95

 Check to make sure the FireChek pneumatic fusible link (in-line in the air line
right before the solenoid that opens to let air actuate the valve) is not tripped.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 96

 Rest FireChek brand fusible link by twisting knurled ring ¼ turn.

Check to see if Master Solenoid is working. Solenoid could have debris in it or is

not working, or the coil could be bad. Note that the Master Solenoid is different
than the solenoids on each actuated valve. The Master Solenoid is 12 volt while
the individual valve solenoids are 24 volts. Note, the Master is ¼” NPT; the
others are 1/8” NPT.

Fill nozzle is leaking during a fill.

Replace energized seal (manufacturer recommends every quarter or when

leaking).

The Saturation Pressure value displayed when recirculating is not correct.

Check the RTD sensor and its wiring. Replace if bad.

The tank or pump discharge pressure values displayed are erroneous (does not
match the liquid level gauge on the gauge panel).

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 97

 Check the applicable pressure transducer and its wiring. Replace if bad.

The liquid level value displayed is not correct (does not match the liquid level
gauge on the gauge panel).

Check the differential pressure transducer and its wiring. Repair or replace.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT 2012) 98

APPENDIX A – Piping Schematic
Revised 6-22-2012

A
(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)
 A
(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)
APPENDIX B – ELECTRICAL SCHEMATICS (INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

NOTE: below is a general shop wiring electrical schematic and wiring table. InoxCVA has a complete set of control syst4em electrical schematics that
are considered proprietary / competition sensitive information. Those schematics can be supplied to the customer on an as-needed basis but may
require that the customer sign a non-disclosure agreement with InoxCVA.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

B
(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)
B
(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)
B
APPENDIX C – PNEUMATIC SCHEMATIC

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

C
APPENDIX D – TC-34 Submerged Pump Curve, and Optional LNG @ 6000 PRM &
TC-30 External Pump @ 4400 RPM. TC-34KA Submerged Pump Curve LNG @
7200 RPM.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

D
(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)
D
(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)
D
(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)
D
APPENDIX E – Liquid Level Charts
LIQUID LEVEL CONVERSION CHART
CVA-16.1K-175-MDT w/ 0% Slope LNG @ 0.0 psig

IN. H20 GALLONS POUNDS MSCF IN. H20 GALLONS POUNDS MSCF
0.5 37 130 3.1 20.5 8,300 29,356 693.2
1.0 104 368 8.7 21.0 8,558 30,268 714.7
1.5 191 675 15.9 21.5 8,815 31,178 736.2
2.0 293 1,037 24.5 22.0 9,072 32,086 757.7
2.5 409 1,446 34.1 22.5 9,328 32,992 779.0
3.0 536 1,896 44.8 23.0 9,583 33,894 800.3
3.5 674 2,382 56.3 23.5 9,837 34,793 821.6
4.0 821 2,903 68.5 24.0 10,090 35,687 842.7
4.5 976 3,454 81.5 24.5 10,341 36,576 863.7
5.0 1,140 4,033 95.2 25.0 10,591 37,459 884.5
5.5 1,311 4,638 109.5 25.5 10,839 38,336 905.2
6.0 1,489 5,268 124.4 26.0 11,085 39,206 925.8
6.5 1,674 5,921 139.8 26.5 11,328 40,068 946.1
7.0 1,865 6,595 155.7 27.0 11,570 40,921 966.3
7.5 2,061 7,289 172.1 27.5 11,808 41,765 986.2
8.0 2,262 8,002 189.0 28.0 12,044 42,600 1,005.9
8.5 2,469 8,733 206.2 28.5 12,277 43,423 1,025.3
9.0 2,680 9,480 223.9 29.0 12,507 44,235 1,044.5
9.5 2,896 10,243 241.9 29.5 12,733 45,035 1,063.4
10.0 3,116 11,021 260.2 *30.0 12,955 45,821 1,082.0
10.5 3,340 11,812 278.9 30.5 13,173 46,594 1,100.2
11.0 3,567 12,616 297.9 31.0 13,388 47,351 1,118.1
11.5 3,798 13,432 317.2 31.5 13,597 48,093 1,135.6
12.0 4,032 14,260 336.7 32.0 13,802 48,817 1,152.7
12.5 4,269 15,098 356.5 32.5 14,002 49,524 1,169.4
13.0 4,508 15,945 376.5 33.0 14,196 50,211 1,185.6
13.5 4,750 16,802 396.7 33.5 14,385 50,878 1,201.4
14.0 4,995 17,666 417.2 34.0 14,567 51,522 1,216.6
14.5 5,241 18,539 437.8 34.5 14,743 52,144 1,231.3
15.0 5,490 19,418 458.5 35.0 14,911 52,740 1,245.4
15.5 5,740 20,303 479.4 35.5 15,072 53,309 1,258.8
16.0 5,992 21,194 500.5 36.0 15,225 53,850 1,271.6
16.5 6,245 22,090 521.6 36.5 15,369 54,358 1,283.6
17.0 6,500 22,990 542.9 37.0 15,503 54,833 1,294.8
17.5 6,755 23,894 564.2 37.5 15,626 55,269 1,305.1

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

E
 18.0 7,012 24,800 585.6 38.0 15,737 55,662 1,314.3
18.5 7,269 25,709 607.1 38.5 15,834 56,005 1,322.4
19.0 7,526 26,620 628.6 39.0 15,915 56,290 1,329.2
19.5 7,784 27,532 650.1 39.5 15,973 56,496 1,334.1
20.0 8,042 28,444 671.7 40.0 15,992 56,564 1,335.6
* - Maximum Capacity: 45,858 Pounds

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

E
 LIQUID LEVEL CONVERSION CHART
CVA-16.1K-175-MDT w/ 0% Slope LNG @ 0.0 psig

IN. H20 LITERS KGS SCM IN. H20 LITERS KGS SCM
0.5 139 59 87 20.5 31,418 13,316 19,629
1.0 393 167 246 21.0 32,394 13,729 20,238
1.5 722 306 451 21.5 33,368 14,142 20,847
2.0 1,109 470 693 22.0 34,340 14,554 21,454
2.5 1,547 656 967 22.5 35,309 14,965 22,060
3.0 2,029 860 1,267 23.0 36,275 15,374 22,663
3.5 2,550 1,081 1,593 23.5 37,237 15,782 23,264
4.0 3,107 1,317 1,941 24.0 38,194 16,187 23,862
4.5 3,696 1,566 2,309 24.5 39,145 16,591 24,456
5.0 4,316 1,829 2,696 25.0 40,091 16,991 25,047
5.5 4,964 2,104 3,101 25.5 41,029 17,389 25,633
6.0 5,638 2,390 3,522 26.0 41,960 17,783 26,215
6.5 6,337 2,686 3,959 26.5 42,882 18,174 26,791
7.0 7,058 2,991 4,410 27.0 43,796 18,561 27,362
7.5 7,801 3,306 4,874 27.5 44,699 18,944 27,926
8.0 8,564 3,630 5,351 28.0 45,592 19,323 28,484
8.5 9,346 3,961 5,839 28.5 46,473 19,696 29,035
9.0 10,146 4,300 6,339 29.0 47,342 20,065 29,578
9.5 10,963 4,646 6,849 29.5 48,198 20,427 30,112
10.0 11,795 4,999 7,369 *30.0 49,040 20,784 30,638
10.5 12,642 5,358 7,898 30.5 49,867 21,135 31,155
11.0 13,502 5,723 8,436 31.0 50,677 21,478 31,661
11.5 14,376 6,093 8,981 31.5 51,471 21,814 32,157
12.0 15,261 6,468 9,535 32.0 52,246 22,143 32,641
12.5 16,158 6,848 10,095 32.5 53,002 22,464 33,114
13.0 17,065 7,233 10,662 33.0 53,738 22,775 33,573
13.5 17,982 7,621 11,234 33.5 54,451 23,078 34,019
14.0 18,907 8,013 11,813 34.0 55,142 23,370 34,450
14.5 19,841 8,409 12,396 34.5 55,807 23,652 34,866
15.0 20,782 8,808 12,984 35.0 56,445 23,923 35,264
15.5 21,729 9,209 13,576 35.5 57,054 24,181 35,645
16.0 22,683 9,614 14,171 36.0 57,632 24,426 36,006
16.5 23,642 10,020 14,770 36.5 58,177 24,657 36,347
17.0 24,605 10,428 15,372 37.0 58,684 24,872 36,664

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

E
 17.5 25,572 10,838 15,976 37.5 59,151 25,069 36,955
18.0 26,542 11,249 16,583 38.0 59,571 25,248 37,218
18.5 27,515 11,662 17,190 38.5 59,939 25,404 37,448
19.0 28,490 12,075 17,799 39.0 60,244 25,533 37,638
19.5 29,466 12,488 18,409 39.5 60,465 25,626 37,776
20.0 30,442 12,902 19,019 40.0 60,537 25,657 37,821
* - Maximum Capacity: 20,801 Kilograms

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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 LIQUID LEVEL CONVERSION CHART
CVA-16.1K-175-MDT w/ 0% Slope LNG @ 10.0 psig

IN.
IN. H20 GALLONS POUNDS MSCF GALLONS POUNDS MSCF
H20
0.5 38 131 3.1 20.0 8,276 28,625 675.9
1.0 107 372 8.8 20.5 8,540 29,537 697.5
1.5 197 682 16.1 21.0 8,803 30,448 719.0
2.0 303 1,048 24.8 21.5 9,066 31,356 740.4
2.5 423 1,462 34.5 22.0 9,328 32,262 761.8
3.0 554 1,916 45.3 22.5 9,588 33,164 783.1
3.5 696 2,408 56.9 23.0 9,848 34,063 804.3
4.0 848 2,934 69.3 23.5 10,107 34,957 825.4
4.5 1,009 3,491 82.4 24.0 10,364 35,846 846.4
5.0 1,178 4,076 96.2 24.5 10,619 36,729 867.3
5.5 1,355 4,687 110.7 25.0 10,872 37,605 888.0
6.0 1,539 5,323 125.7 25.5 11,123 38,473 908.5
6.5 1,730 5,982 141.3 26.0 11,372 39,334 928.8
7.0 1,926 6,663 157.3 26.5 11,619 40,186 948.9
7.5 2,129 7,363 173.9 27.0 11,862 41,028 968.8
8.0 2,337 8,083 190.9 27.5 12,103 41,860 988.4
8.5 2,550 8,820 208.3 28.0 12,340 42,681 1,007.8
9.0 2,768 9,573 226.1 28.5 12,574 43,490 1,026.9
9.5 2,990 10,343 244.2 29.0 12,804 44,286 1,045.7
10.0 3,217 11,126 262.7 29.5 13,030 45,068 1,064.2
10.5 3,447 11,924 281.6 30.0* 13,252 45,836 1,082.3
11.0 3,682 12,734 300.7 30.5 13,469 46,588 1,100.1
11.5 3,919 13,556 320.1 31.0 13,682 47,323 1,117.4
12.0 4,160 14,389 339.8 31.5 13,889 48,040 1,134.4
12.5 4,404 15,233 359.7 32.0 14,091 48,739 1,150.9
13.0 4,651 16,086 379.8 32.5 14,287 49,417 1,166.9
13.5 4,900 16,947 400.2 33.0 14,477 50,073 1,182.4
14.0 5,151 17,817 420.7 33.5 14,660 50,707 1,197.3
14.5 5,405 18,694 441.4 34.0 14,836 51,316 1,211.7
15.0 5,660 19,577 462.3 34.5 15,005 51,898 1,225.5
15.5 5,917 20,467 483.3 35.0 15,165 52,451 1,238.5
16.0 6,176 21,361 504.4 35.5 15,315 52,973 1,250.8
16.5 6,436 22,260 525.6 36.0 15,457 53,461 1,262.4
17.0 6,697 23,163 547.0 36.5 15,587 53,911 1,273.0

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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 17.5 6,959 24,070 568.4 37.0 15,705 54,320 1,282.7
18.0 7,222 24,978 589.8 37.5 15,809 54,680 1,291.2
18.5 7,485 25,889 611.3 38.0 15,897 54,984 1,298.3
19.0 7,749 26,801 632.8 38.5 15,964 55,215 1,303.8
19.5 8,012 27,713 654.4 39.0 15,996 55,325 1,306.4
* - Maximum Capacity: 45,858 Pounds

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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 LIQUID LEVEL CONVERSION CHART
CVA-16.1K-175-MDT w/ 0% Slope LNG @ 10.0 psig

IN. H20 LITERS KGS SCM IN. H20 LITERS KGS SCM
0.5 144 60 88 20.0 31,329 12,984 19,140
1.0 407 169 249 20.5 32,327 13,398 19,750
1.5 747 309 456 21.0 33,323 13,811 20,359
2.0 1,147 475 701 21.5 34,317 14,223 20,966
2.5 1,600 663 977 22.0 35,308 14,634 21,572
3.0 2,097 869 1,281 22.5 36,296 15,043 22,175
3.5 2,636 1,092 1,610 23.0 37,280 15,451 22,776
4.0 3,211 1,331 1,962 23.5 38,258 15,856 23,374
4.5 3,820 1,583 2,334 24.0 39,231 16,259 23,968
5.0 4,461 1,849 2,725 24.5 40,197 16,660 24,558
5.5 5,130 2,126 3,134 25.0 41,156 17,057 25,144
6.0 5,826 2,415 3,559 25.5 42,107 17,451 25,725
6.5 6,547 2,713 4,000 26.0 43,049 17,842 26,301
7.0 7,292 3,022 4,455 26.5 43,981 18,228 26,870
7.5 8,059 3,340 4,923 27.0 44,903 18,610 27,433
8.0 8,846 3,666 5,404 27.5 45,814 18,988 27,990
8.5 9,653 4,001 5,897 28.0 46,712 19,360 28,539
9.0 10,477 4,342 6,401 28.5 47,597 19,727 29,079
9.5 11,319 4,691 6,916 29.0 48,468 20,088 29,612
10.0 12,177 5,047 7,440 29.5 49,324 20,443 30,135
10.5 13,050 5,409 7,973 30.0* 50,164 20,791 30,648
11.0 13,937 5,776 8,515 30.5 50,987 21,132 31,151
11.5 14,836 6,149 9,064 31.0 51,792 21,465 31,642
12.0 15,748 6,527 9,621 31.5 52,577 21,791 32,122
12.5 16,671 6,909 10,185 32.0 53,341 22,108 32,589
13.0 17,605 7,296 10,756 32.5 54,084 22,415 33,042
13.5 18,548 7,687 11,332 33.0 54,802 22,713 33,481
14.0 19,500 8,082 11,913 33.5 55,495 23,000 33,905
14.5 20,459 8,479 12,500 34.0 56,162 23,276 34,312
15.0 21,426 8,880 13,090 34.5 56,799 23,540 34,701
15.5 22,400 9,284 13,685 35.0 57,404 23,791 35,071
16.0 23,379 9,689 14,283 35.5 57,975 24,028 35,420
16.5 24,363 10,097 14,884 36.0 58,510 24,249 35,746
17.0 25,351 10,507 15,488 36.5 59,003 24,454 36,048

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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 17.5 26,343 10,918 16,094 37.0 59,450 24,639 36,321
18.0 27,337 11,330 16,702 37.5 59,844 24,803 36,562
18.5 28,334 11,743 17,310 38.0 60,176 24,940 36,765
19.0 29,332 12,157 17,920 38.5 60,429 25,045 36,919
19.5 30,330 12,570 18,530 39.0 60,550 25,095 36,993
* - Maximum Capacity: 20,801 Kilograms

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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 LIQUID LEVEL CONVERSION CHART
CVA-16.1K-175-MDT w/ 0% Slope LNG @ 60.0 psig

IN.
IN. H20 GALLONS POUNDS MSCF GALLONS POUNDS MSCF
H20
0.5 42 136 3.2 18.5 8,179 26,418 623.8
1.0 119 385 9.1 19.0 8,461 27,330 645.3
1.5 219 706 16.7 19.5 8,743 28,241 666.9
2.0 336 1,084 25.6 20.0 9,025 29,150 688.3
2.5 468 1,512 35.7 20.5 9,305 30,057 709.7
3.0 613 1,981 46.8 21.0 9,585 30,960 731.1
3.5 771 2,489 58.8 21.5 9,863 31,859 752.3
4.0 939 3,032 71.6 22.0 10,140 32,753 773.4
4.5 1,116 3,606 85.2 22.5 10,415 33,641 794.4
5.0 1,303 4,209 99.4 23.0 10,688 34,523 815.2
5.5 1,498 4,839 114.3 23.5 10,959 35,398 835.8
6.0 1,701 5,494 129.7 24.0 11,227 36,264 856.3
6.5 1,911 6,173 145.8 24.5 11,492 37,121 876.5
7.0 2,128 6,873 162.3 25.0 11,755 37,969 896.6
7.5 2,351 7,593 179.3 25.5 12,014 38,806 916.3
8.0 2,579 8,332 196.7 26.0 12,269 39,631 935.8
8.5 2,814 9,088 214.6 26.5 12,521 40,444 955.0
9.0 3,053 9,861 232.9 27.0 12,769 41,243 973.9
9.5 3,297 10,650 251.5 27.5 13,011 42,028 992.4
10.0 3,546 11,452 270.4 28.0 13,250 42,797 1,010.6
10.5 3,798 12,268 289.7 28.5 13,482 43,549 1,028.3
11.0 4,055 13,097 309.3 29.0 13,710 44,284 1,045.7
11.5 4,315 13,936 329.1 29.5 13,931 44,999 1,062.6
12.0 4,578 14,786 349.2 30.0* 14,146 45,694 1,079.0
12.5 4,844 15,646 369.5 30.5 14,355 46,366 1,094.9
13.0 5,113 16,514 390.0 31.0 14,556 47,015 1,110.2
13.5 5,384 17,391 410.7 31.5 14,749 47,639 1,124.9
14.0 5,658 18,274 431.5 32.0 14,933 48,235 1,139.0
14.5 5,933 19,164 452.5 32.5 15,109 48,802 1,152.4
15.0 6,210 20,059 473.7 33.0 15,274 49,336 1,165.0
15.5 6,489 20,959 494.9 33.5 15,429 49,835 1,176.8
16.0 6,769 21,864 516.3 34.0 15,571 50,295 1,187.6
16.5 7,050 22,771 537.7 34.5 15,700 50,711 1,197.4
17.0 7,331 23,681 559.2 35.0 15,813 51,076 1,206.1

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 17.5 7,614 24,592 580.7 35.5 15,907 51,381 1,213.3
18.0 7,896 25,505 602.2 36.0 15,977 51,608 1,218.6
* - Maximum Capacity: 45,858 Pounds

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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 LIQUID LEVEL CONVERSION CHART
CVA-16.1K-175-MDT w/ 0% Slope LNG @ 60.0 psig

IN. H20 LITERS KGS SCM IN. H20 LITERS KGS SCM
0.5 159 62 91 18.5 30,960 11,983 17,664
1.0 451 175 257 19.0 32,029 12,397 18,274
1.5 827 320 472 19.5 33,097 12,810 18,883
2.0 1,271 492 725 20.0 34,162 13,222 19,491
2.5 1,771 686 1,011 20.5 35,225 13,634 20,097
3.0 2,322 899 1,325 21.0 36,283 14,043 20,701
3.5 2,917 1,129 1,665 21.5 37,337 14,451 21,302
4.0 3,553 1,375 2,027 22.0 38,384 14,857 21,900
4.5 4,226 1,636 2,411 22.5 39,425 15,259 22,494
5.0 4,933 1,909 2,815 23.0 40,459 15,659 23,084
5.5 5,671 2,195 3,236 23.5 41,484 16,056 23,668
6.0 6,439 2,492 3,674 24.0 42,499 16,449 24,248
6.5 7,234 2,800 4,127 24.5 43,504 16,838 24,821
7.0 8,054 3,117 4,595 25.0 44,497 17,222 25,388
7.5 8,898 3,444 5,077 25.5 45,478 17,602 25,947
8.0 9,764 3,779 5,571 26.0 46,445 17,976 26,499
8.5 10,651 4,122 6,077 26.5 47,397 18,345 27,043
9.0 11,557 4,473 6,594 27.0 48,334 18,708 27,577
9.5 12,481 4,831 7,121 27.5 49,254 19,064 28,102
10.0 13,421 5,195 7,658 28.0 50,155 19,412 28,616
10.5 14,378 5,565 8,203 28.5 51,037 19,754 29,119
11.0 15,348 5,941 8,757 29.0 51,897 20,087 29,610
11.5 16,332 6,321 9,318 29.5 52,736 20,411 30,088
12.0 17,329 6,707 9,887 30.0* 53,550 20,726 30,553
12.5 18,336 7,097 10,462 30.5 54,338 21,031 31,003
13.0 19,354 7,491 11,042 31.0 55,099 21,326 31,437
13.5 20,381 7,888 11,628 31.5 55,830 21,609 31,854
14.0 21,416 8,289 12,219 32.0 56,528 21,879 32,252
14.5 22,459 8,693 12,814 32.5 57,192 22,136 32,631
15.0 23,508 9,099 13,413 33.0 57,819 22,379 32,988
15.5 24,563 9,507 14,014 33.5 58,403 22,605 33,322
16.0 25,623 9,917 14,619 34.0 58,942 22,813 33,630
16.5 26,686 10,329 15,226 34.5 59,429 23,002 33,908
17.0 27,752 10,741 15,834 35.0 59,858 23,168 34,152

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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 17.5 28,820 11,155 16,443 35.5 60,215 23,306 34,356
18.0 29,890 11,569 17,054 36.0 60,481 23,409 34,507
* - Maximum Capacity: 20,801 Kilograms

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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APPENDIX F – GENERAL ARRANGEMENT DRAWING

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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OTHER APPENDICES
Please see electronic files on CD shipped with this manual for copies of the
manufacturer’s manuals for subcomponents used on this system.

(INOX-CVA PROPRIETARY INFORMATION – COPYRIGHT)

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