Manual PRS Imw

ISO 9001 43676 Progress Way Tel: (604) 795-9491
Chilliwack Fax: (604) 792-3806

British Columbia info@imw.ca
Canada V2R 0C3 www.imw.ca
IMW-PRS PRESSURE REDUCTION SYSTEM

Installation, Operation and Maintenance Manual
(For illustration purposes only. May not represent actual product delivered)
PRM S/N: WC1007909 HCM S/N WC1005735
Customer name: CEDP TRUJILLO Installation date: JUNE 2013
COPY ___ OF ___
CM-2012-002-Rev. 0 June 2012

IMW-PRS Pressure Reduction System
IMW-PRS Release Date: June 2012 Page 2 of 48

Table of Contents
IMW-PRS Pressure Reduction System ........................................................................................................................1
Table of Contents .......................................................................................................................................................3
I. Document Revision History ............................................................................................................................7
II. DISCLAIMERS ..................................................................................................................................................7
III. Purpose ...........................................................................................................................................................7
IV. Scope ..............................................................................................................................................................7
V. Safe Work Practices ........................................................................................................................................8
VI. Roles and Responsibilities of the Qualified Maintenance Personnel .............................................................8
VII. Roles and Responsibilities of the Operation Personnel .................................................................................8
1. Who we are and what we do... ......................................................................................................................9
2. Service Centers ............................................................................................................................................ 10
3. Authorized Representatives ........................................................................................................................ 11
4. General Description ..................................................................................................................................... 12
5. General safety information and emergency response procedures............................................................. 13
5.1. Safety ........................................................................................................................................................... 13
5.2. Visual communication ................................................................................................................................. 13
5.2.1. Danger Symbols ............................................................................................................................... 13
5.2.2. Warning Symbols ............................................................................................................................. 14
5.2.3. Safety equipment symbols .............................................................................................................. 14
5.3. Safety instructions ....................................................................................................................................... 15
5.3.1. Local safety regulations ................................................................................................................... 15
5.3.2. Entering a hazardous environment ................................................................................................. 15
5.3.3. Lock-out procedure ......................................................................................................................... 15
5.3.4. Opening the electrical cabinet......................................................................................................... 16
5.3.5. Safety remarks regarding operation................................................................................................ 16
5.3.6. Safety remarks in case of gas leaks ................................................................................................. 17
5.3.7. Arc flash and arc blast hazards ........................................................................................................ 17
5.3.8. Arc Flash Hazard Analyses ............................................................................................................... 18
6. Pressure Reduction System Modules .......................................................................................................... 19
6.1. Pressure reduction module ......................................................................................................................... 19
6.1.1. Regulators identification ................................................................................................................. 20

6.1.2. Standby monitor .............................................................................................................................. 20

6.1.3. Working monitor ............................................................................................................................. 20
6.1.4. Pilot operated regulator set-point adjustment ............................................................................... 21
6.2. Heating control module - HCM.................................................................................................................... 22
6.3. PRM/HCM Control module – Description ................................................................................................... 23
7. Installation ................................................................................................................................................... 24
7.1. PRM/HCM installation ................................................................................................................................. 24
7.1.1. General considerations.................................................................................................................... 24
7.1.2. Physical placement and securing..................................................................................................... 24
7.1.3. Concrete foundation ....................................................................................................................... 25
7.1.4. Skid bolt down ................................................................................................................................. 25
7.1.5. HCM shelter provisions ................................................................................................................... 26
7.1.6. HCM vent provisions ....................................................................................................................... 26
7.1.7. Automatic vent damper (if applicable)............................................................................................ 27
7.1.8. Vent terminal information............................................................................................................... 27
7.1.9. Pressure relief valve and discharge pipe ......................................................................................... 28
7.1.10. Site piping ........................................................................................................................................ 28
7.1.11. Cathodic Protection ......................................................................................................................... 28
7.1.12. Isolation Valves ................................................................................................................................ 29
7.1.13. Boiler operating requirements ........................................................................................................ 29
7.1.14. Area electrical classifications ........................................................................................................... 29
7.1.15. Electrical control panel installation ................................................................................................. 30
7.1.16. Electrical field wiring connections ................................................................................................... 30
7.1.17. Blocked vent and flame roll-out safety switches (if applicable)...................................................... 30
8. Start-up and commissioning ........................................................................................................................ 31
8.1. Start-up preparation.................................................................................................................................... 31
8.2. Start-up procedures..................................................................................................................................... 31
8.2.1. Pre-start-up check list (first operation) - Gas .................................................................................. 31
8.2.2. PRM Piping Nitrogen Purge ............................................................................................................. 32
8.2.3. Pre-start-up check list – Water ........................................................................................................ 32
9. Operation..................................................................................................................................................... 33
9.1. Initial operation ........................................................................................................................................... 33

9.2. Running operation ....................................................................................................................................... 34

9.3. Running conditions ...................................................................................................................................... 34
9.4. Alarms and warnings ................................................................................................................................... 35
9.4.1. Alarms list ........................................................................................................................................ 35
9.4.2. Warnings list .................................................................................................................................... 36
9.5. Alarm History ............................................................................................................................................... 36
9.6. Stopping operation ...................................................................................................................................... 36
9.7. Setpoints ...................................................................................................................................................... 37
9.7.1. Altering setpoints ............................................................................................................................ 37
9.8. Misc screen .................................................................................................................................................. 38
10. Optional Equipment .................................................................................................................................... 39
10.1. Voltage monitor........................................................................................................................................... 39
10.2. Uninterrupted power supply (UPS) ............................................................................................................. 39
10.2.1. UPS minimum requirements ........................................................................................................... 39
10.2.2. UPS installation ................................................................................................................................ 40
10.2.3. Additional options ........................................................................................................................... 40
11. Maintenance and Troubleshooting ............................................................................................................. 41
11.1. Elements of maintenance interest .............................................................................................................. 41
11.1.1. Inlet Filter ........................................................................................................................................ 41
11.1.2. Pressure transmitters ...................................................................................................................... 41
11.1.3. Shell and tube heat exchanger ........................................................................................................ 41
11.1.4. Boiler................................................................................................................................................ 42
11.1.5. Relief valves ..................................................................................................................................... 42
11.1.6. Vent header ..................................................................................................................................... 42
11.1.7. Low water flow cut-off switch ......................................................................................................... 42
11.1.8. Strainer ............................................................................................................................................ 43
11.1.9. Pump................................................................................................................................................ 43
11.2. Preventive maintenance (PM) schedule ..................................................................................................... 43
11.3. Torque recommendation ............................................................................................................................ 44
11.4. Maintenance records template ................................................................................................................... 44
11.5. Parts ordering procedure ............................................................................................................................ 46
11.5.1. Parts under warranty....................................................................................................................... 46

11.5.2. Parts out of warranty....................................................................................................................... 47

11.5.3. Technical support and field service calls ......................................................................................... 47

I. Document Revision History

Revision Date Updated by Section Approved by
0 June, 2011 DDestro First release ENG, AM, QA
II. DISCLAIMERS
TM & ® 2011 IMW Industries, (a division of Clean Energy Corp.) All rights reserved. This document is the
product of intensive creative efforts, and contains confidential trade information belonging to IMW
Industries. Unauthorized duplication of material contained in this document could be damaging to IMW
Industries. No disclosure, distribution, or reproduction of this material may be made without prior written
authorization from IMW industries. Unauthorized use, disclosure, dissemination, or duplication of any of the
information contained herein may result in liability under applicable laws.
This manual is intended for qualified personnel only. IMW Industries assumes no responsibilities for injuries,
or damage to property resulting for the misuse, or the misinterpretation of information contained herein.
IMW Industries has made all reasonable efforts to present here the most up-to-date information available at
the time of publication. However, some items may not reflect exactly what is found in the product delivered.
In case of discrepancies, contact IMW immediately.
IMW Industries is ISO 9001-certified, and builds equipment under electrical and mechanical norms such as
CE, ATEX, ASME, and PED, among others. The compliance with specific norms vary with the final product
delivered. For more information about the conformity characteristics of this specific product, consult the
related declarations found in this document package.
III. Purpose
The purpose of this manual is to provide Operators and Local Maintenance Personnel with the information
necessary to operate, maintain, troubleshoot, and perform simple repairs. The information and procedures
for these activities outlined in this manual are deemed adequate and sufficient by IMW Industries.
IV. Scope
This manual provides information for the deployment, use and upkeep of the systems under normal
situations, including descriptions of routine inspections, routine adjustments, and preventive maintenance
activities. A set of relevant OEM documents completes this manual. The OEM Documents are the
responsibility of its publishers. This Manual does not cover extensive maintenance procedures or
retrofitting, nor is it intended for personnel training.
If information beyond the scope of this manual is required, please contact:

IMW Industries
43676 Progress Way
Chilliwack, BC V2R 0C3 Canada
www.imw.ca +1-604-795-9491
or one of its representatives.

V. Safe Work Practices

All maintenance routines should comply with CCOHS (in Canada) or OSHA (in the USA) occupational safety
standards, and local work safety regulations. In case of doubt, consult IMW Industries, or your local work
safety regulatory agency for more information.
All operation and maintenance personnel must be properly trained and supervised by qualified
professionals. No personnel should be allowed to perform ANY routine described in this manual without
proper training and supervision.
Due to the large energy employed, and the presence of a flammable gas throughout the system, it is
strongly recommended that all maintenance routines be performed by a team of at least two trained
professionals.
VI. Roles and Responsibilities of the Qualified Maintenance Personnel

Only qualified maintenance personnel trained by IMW Industries, or its representatives, should be
responsible for maintaining system performance, while ensuring safety in and around the system.
The job of the maintenance personnel is to guarantee that the whole system performs within the specified
levels of quality and safety throughout the life of the system. For this purpose they must:
• not propose, accept, or condone any compromise regarding performance and safety for reasons of
expediency, or otherwise;
• ensure that all tools, instruments and emergency response devices necessary,
are available and operational at all times;
• apply cascading safety devices such as hasps, padlocks, and restraining stripes
and barriers, whenever maintenance procedures are performed.
VII. Roles and Responsibilities of the Operation Personnel

All operators should be adequately trained to perform their duties efficiently and safely. The following topics
should be understood and followed by all operation personnel. The operators must:
• immediately report to the system supervisor any discrepancy in normal operating conditions;
• request, use, make available to subordinates, and insist on the proper utilization of all safety
equipment;
• respect safety labels, warning signs, and written instructions without compromise or
interpretations;
• ensure that all tools, instruments and emergency response devices necessary are available and
operational at all times;
• understand and be capable of operating safety devices such as Emergency Stop Devices (ESD).

1. Who we are and what we do...
Welcome to IMW Full in-house capabilities…
IMW designs, manufactures, and supports a full …for designing and building complete CNG
range of fill posts and compressor systems. We refuelling systems make IMW Compressor
specialize in compressed natural gas (CNG) Systems a single-source supplier of CNG
compressors, and complete fuelling systems. equipment. We offer an extensive range of
standard and custom CNG products, and
Experience gained through our general machine maintain a large inventory of components to
shop and manufacturing operations has led to facilitate same-day response to our customers’
cutting-edge technologies and the know-how to requests, whenever possible. Qualified
meet increasingly complex demands worldwide. technicians, meanwhile, are available around-
the-clock for consultation or for service dispatch
State-of-the-art… globally.
…CNG refuelling systems have earned IMW a Innovative…

worldwide reputation for quality, performance,
and reliability through precision engineering and …compressor technology is the foundation of
manufacturing. IMW employs only the highest- IMW’s CNG refuelling systems. IMW is a pioneer
quality components in its systems, including in the development and production of low-
integrated PLC controls and custom-designed speed, non-lubricated compressors and of
compressor assemblies, available exclusively complete, high-volume transit fuelling systems.
from IMW Industries. In-house capabilities and a Our CNG compressors produce clean gas—low in
commitment to growth ensure that our products oil content—while operating at low noise and
remain affordable. vibration levels, thereby enhancing system
usability and component life. Yet they boast a
discharge flow capacity equal to any compressor
on the market.

2. Service Centers
CANADA USA
IMW Industries IMW Industries Inc.

43676 Progress Way 6943 Salashan Pkwy
Chilliwack, BC, Canada V2R 0C3 Ferndale, Washington
Phone: +1+604-795-9491 United States of America
No. America: +1-877-446-9648 (toll free) Phone: +1-209-366-3491
Fax: +1-604-792-3806 No. America +1-877-446-9648 (toll free)
aftermarket@imw.ca aftermarket@imw.ca
CHINA BANGLADESH
IMW Compressors (Shanghai) Co., Ltd. IMW CNG Bangladesh Ltd.

Room 501, Building 9, 1888 Xin Jin Qiao Road, House# 376/A (3rd Floor), Road# 28,
Pudong, Shanghai, P.R.C. 201206 New DOHS, Mohakhali,
Phone: +86-21-33820102 Dhaka- 1206, Bangladesh
Fax: +86-21-33820109 Phone: +88-01730044450-1
asia-aftermarket@cn.imw.ca info@imwbd.com
COLOMBIA
IMW Colombia Ltda.

Via 40 #69 - 58 Bodega A-1
Parque Industrial Via 40
Barranquilla, Colombia
Phone: +57-5-344-3171 / 5-344-3454
Fax: +57-5-360-1236
imwcolombia@co.imw.ca

3. Authorized Representatives
NIGERIA MALAYSIA
NG Equipment & Systems Limited. Spectron SDN BHD

# 12 Atunwa Street 2ND Floor, No. 57, Jalan BP 6/7
Off Unity Road, Ikeja Lagos Bandar Bukit Puchong
Nigeria 47120 Puchong, Selangor, Malaysia
Phone: +234-1-8941434 Phone: +603-8068 5593
Fax: +234-1-2557857 Fax: +603-8061 4968
sales@cngequipment.com general@spectron.com.my
PAKISTAN CZECH REPUBLIC
Allied Engineering Services Limited Bonett Bohemia, a.s.

21/3, Sector No.22, Korangi Industrial Area, Sudomerska 1293/32
Karachi-74900 Prague 3
Pakistan 13000
G.P.O.Box 940 Czech Republic
Phone: +92-21-111-250-250 Phone: +420-222-801-911
Fax: +92-21-5066915 Fax: +420-222-801-917
compressor@aesl.com.pk servis@bonett.cz
THAILAND
Polytechnology co.,ltd.
108/59 Soi Tonson, Cheangwattana Road
Pakkred, Nonthaburi 11120
Thailand
Phone: +66-2-9605070 Ext # 214 , 212
Fax: +66-2-584-6771
phuttipong@polytech.co.th

4. General Description
Each Pressure Reduction System (PRS) consists of two major components: the Pressure Reduction Module (PRM)
and the Heating Control Module (HCM).
The PRM consists of an inlet filter, gas-to-water heat exchanger, gas regulation devices, piping, and electrical
controls. Metering may be provided as an option.
The HCM consists of a water boiler fuelled by natural gas, a gas regulation device, water flow meter, air separator,
strainer, and pump.
In many installations, expanding gas from storage (fixed or mobile) flows to the PRM where it is filtered and heated
by a heat exchanger, which received hot water from HCM. The gas is then regulated down, metered, and
discharged.
The HCM heats and pumps water through a continuous loop to the PRM. It burns a relativelly small quantity of
natural gas supplied by the PRM.
The low pressure gas at the PRM discharge outlet flange is ready to be piped to fuel consuming equipment such as
boilers, heaters, stationary engines, or other devices.
The electrical controls for each of the major components are housed within their assembly or remotely mounted in
an enclosure appropriate to the area rating. The electrical controls include an emergency shutdown device (ESD).
The specific configuration of your system and its components can be determined from the drawings, schematics,
components lists, and parts literature found in other sections of this documentation package.

5. General safety information and emergency response procedures
5.1. Safety
Safety must always be the prime concern of all personnel involved in the operation and maintenance of any system
that employs, like the IMW-PRS, pressurized natural gas, high-power motors, and electrical controls. DO NOT
attempt to perform the tasks described in this manual, if you are not fully qualified.
It is absolutely essential that all safety devices and emergency response system be fully operational, and within their
certification periods, before any operation or service can be allowed at the IMW-PRS.
The following symbols may be present in different parts of the IMW-PRS, or in its vicinity. Ensure that you, and your
co-workers, understand their meaning, and the reason why they are placed at that location.
5.2. Visual communication

IMW Industries uses extensive visual aids based on ISO 3864-1/4 safety symbol standards, both on the equipment,
and within this manual. On the equipment, it is essential that all symbols remain in plain sight, clean, and in good
visual condition throughout the life of the equipment. If a symbol is damage or lost, contact IMW Industries for a
replacement immediately.
5.2.1. Danger Symbols

Danger symbols indicate elevated risk of death, severe injury, and catastrophic damage to property, if the
instruction conveyed by the symbol is not strictly followed.
These symbols do not allow for compromise!
Elevated risk of death or injure in case No cigarette, lighter, matches, or other

of accident. All appropriate safety similar material can be lit, or carried
wear and safety devices MUST be into the vicinity.
employed at all times.
No open flame, such as blow torches A fully operational fire extinguisher

or welding equipment, can be used in must present in the area, and rated by
the vicinity. the local safety board for the adequate
class of fire.

5.2.2. Warning Symbols

Warning symbols indicate the risk of death, injury, or damage to property, if overlooked.
General Hazard. There are intrinsic Electrical Hazards. These are risks
risks in the immediate vicinity. Stay related to electrical connections. Wear
alert for sudden changes in sound or electrical protection equipment, such
light. as rubber gloves and insulated shoes.
Risk of explosion, or uncontrolled Risk of catching, crushing, or severing

release of compressed fluids or gas. of limbs. Do not touch moving parts.
Wear eye protection and/or other Do not wear loose fitting clothing.
adequate equipment.
Hot surface. Do not touch or leave Full safety gear (PPE – Certified
objects over the area. Personal Protection Equipment), as
defined by the local safety board, must
be worn at all times.
5.2.3. Safety equipment symbols

The following symbols indicate equipment and/or devices that enhance personal safety. They are mandatory
wherever these symbols are present.
Wear adequate eye protection against Wear foot protection against crushing
impact, fluids, and/or intense light. and penetration hazards
Apply individual padlock protection Wear protective gloves against cuts,

(interlocking lockout hasps) whenever penetration, and heat hazards
maintenance or service is performed

5.3. Safety instructions

It is very important that you READ AND UNDERSTAND the following safety instructions. If you have any question,
consult your safety supervisor, or a person more experienced in this type of system. DO NOT attempt to operate,
service, repair, or clean the equipment unless you fully understand the procedures and risks involved. The following
rules always apply:
• All operation, service, repair, and cleaning work must be done in compliance with local regulations;
• Smoking is strictly forbidden in the proximity of the equipment, and its supply/delivery lines;
• Highly compressed natural gas, even in small quantities, contains a large amount of energy, and can be very
dangerous. Ensure that the entire system is completely vented (open to the atmosphere), before executing any
maintenance or repair work;
• Rotating and moving machine parts represent a special risk of
accidents. Do not remove guards and covers during operation or
energized maintenance routines;
• Do not store easily flammable materials near the compressor unit;
• Do not touch any wiring (exposed or not), or electrical components
when the system is energized;
• If you are not a certified electrician, do not open any electrical cabinet.
5.3.1. Local safety regulations

The following safety instructions are based on WorkSafe BC (WSBC) Occupational Health and Safety (OHS)
Regulation, and may not apply outside British Columbia, Canada. They are provided as guidelines only. For detailed
information, consult WorkSafe BC website. For local-specific regulations, consult your regional agency for health and
safety code standards.
5.3.2. Entering a hazardous environment

• Do not enter the compressor room until it has been established as a safe environment (WSBC - OHS Reg. 4.3);
• When work is performed in the compressor room or storage area, the atmosphere must be monitored for
Oxygen (O2) deficiency and explosive limits in accordance to WSBC – OHS Reg. 9.26;
• When working with or around the container ensure that the area is well ventilated, in accordance to WSBC –
OHS Reg. 9.3
5.3.3. Lock-out procedure

A lock-out procedure means that, by using devices such as padlocks, hasps, and chains, the
equipment, or its modules cannot be energized or recharged by accident while work is being
performed.
The person(s) performing the work must have full and sole control of the locking device at all
times, until the work is completed. Only when all locking devices have been removed can the
equipment be re-energized or recharged.
NOTE: Never make copies of lock-out keys.

• When work is performed in or around the compressor skid, the motor and all electrical components must be
locked-out in accordance to WSBC – OHS Reg. 10.4;
• If work is performed on any electrical component, the entire system, including eventual secondary power
sources, must be de-energized in accordance to WSBC – OHS Reg. 10.2;
• During maintenance work to any of the compressor’s lines, the inlet and discharge lines must be closed and
locked-out by applying chains and padlock to the main valves.
5.3.4. Opening the electrical cabinet

The electrical control panels and cabinets should only be open by qualified and authorized personnel.
Note: Read the compressor and/or panel nameplate for actual hazardous area classification, as they
may change due to specific design criteria.
Before opening any control panel or electrical cabinet, turn the ONLINE/OFFLINE switch to the OFFLINE position, and
lock out the all power supplies to the panel
Before opening explosion-proof panels, the panel location must be declassified in accordance to the following
procedure:
• Lock out the compressor and piping systems within the classified area;
• Purge all compressor and piping systems with nitrogen.
• After completing all work in the explosion-proof panel, if applicable, replace and torque all its bolts before
allowing any gas to refill the compressor or piping.
The equipment is designed for Class I, Division 1 or 2 Group D hazardous or unclassified materials. For area
classifications refer to CSA publication CAN/CSA B149.1 Natural Gas and Propane Installation codes, or equivalent
codes. These codes can be found at the CSA Website.
5.3.5. Safety remarks regarding operation

In order to work productively, the system must be maintained in a safe, clean and stable condition at all times, and
must be inspected regularly. The following instructions intend to guide the operator about good operation practices
in order to maximize performance, and reduce the risk of accidents.
• The system should only operate within its technical specifications. Any situation that forces it beyond its
capacity can be dangerous, both to property and personnel. Operation outside the technical specification may
void the warranty;
• Do not allow or accept modifications to any part of the system, even temporary, as serious consequences may
result. Any modification must be approved in advance by IMW Industries. Unauthorized modifications may void
the warranty;
• Before operating the system, ensure that no one is performing inspection or maintenance work in or around the
system;

• Do not touch any piping – specially discharge piping – or any other part of the system while in operation;
• Never execute any cleaning work while the system is running or energized;
NOTE: Be aware that the compressor may start automatically at any time. Therefore, do not assume
that a compressor that is not running is disconnected or de-energized.
5.3.6. Safety remarks in case of gas leaks

Gas leaks are one of the most dangerous situations around a gas compressor. If a leak is detected, or if you suspect
that a leak exists, take the following actions immediately:
• Isolate the machine by placing the Key Switch in the Offline position;
• Cut all power to the system;
• Isolate the storage banks by closing and locking the ball valves at the storage tanks;
• Purge all gas from the system with nitrogen;
• Locate and repair the leak immediately.
5.3.7. Arc flash and arc blast hazards

Any electrical voltage can produce an arc. In industry an arc, typically referred to
as “ARC FLASH”, is the sudden release of large amounts of energy in the form of
heat and light.
Personal exposure to an arc flash frequently results in a variety of serious

injuries, and in some cases death. Workers may be injured at great distances
from the arc flash, sometimes farther than 4 meters (12 feet) away.
Aside from personal injuries, equipment can be severely damaged resulting in downtime and expensive repair work.
Also, nearby flammable materials may be ignited.
An arc flash produces not only intense heat and light, but also blast pressures and loud sounds. The arc blast often
causes parts of the equipment to explode, ejecting parts, insulation materials, and supporting structures with great
force.
Heated air and vaporized materials surrounding the arc expand rapidly, causing effects comparable to an explosive
charge. As conductors vaporize, they may project molten particles similar to buckshot. Eight (8) centimetres (3
inches) of vaporized a 2.5 mm (AWG 10) copper wire expands to approximately 28 litres (one cubic foot), or more
than 65,000 times its solid volume. Tools, loose nuts, bolts, and similar items in the path of an arc blast may become
projectiles.
The total force reaching a worker standing in front of an open enclosure may exceed 500 Kg (approx 1,000 pounds).
Such forces may crush a worker’s chest, breaking bones, puncturing lungs or other organs, and even propelling
workers into equipment, walls, windows, etc., causing additional trauma.

5.3.8. Arc Flash Hazard Analyses

Conducting an arc flash hazard study is the cornerstone for worker safety when working with high energy equipment
such as the IMW-PRS. The purpose of an arc flash hazard study is to determine the possible location and severity of
arc flash hazards, and to suggest appropriate courses of action to minimize them.
The study requires electrical engineering expertise, and an in-depth knowledge of a facility's electrical system.
For detailed information on how to conduct an Arc Flash test, consult:
Canadian Standards Association - Occupational Health and Safety Program (CSA-OHS)
5060 Spectrum Way

Mississauga, ON L4W 5N6
Toll Free: 1 800 463-6727
http://ohs.csa.ca/index.asp;
or your regional association for engineering standards, testing and occupational safety.

6. Pressure Reduction System Modules
6.1. Pressure reduction module

The IMW Pressure Reduction Module (PRM)
safely reduces gas pressure by adding the
appropriate amount of heat to counter the
temperature reduction due to depressurization.
The inlet line to the PRM is connected to a fixed

or mobile storage, or to a pipeline. The gas
flowing to the PRM passes through a failsafe,
normally-closed inlet valve.
The valve isolates the PRM from the gas supply

whenever the PRM is shut down, or if an
Emergency Shut-Down sequence is initiated.
Small particles are removed from the supply gas

by an inlet filter, located before the heat
exchanger.
Gas flows through a shell & tube heat exchanger. The tubes of gas are kept heated by a stream of hot fluid
(water/glycol) that is pumped through the shell by the HCM, as the gas enters the first stage of pressure regulation
(depressurization). Further stages of regulation may be employed to reach the final output pressure.
Pressure gauges are provided throughout the system for monitoring system gas pressures, and for setting the
regulators.
Supply gas for the boiler is taken from the main

line after the heat exchanger. It may be
regulated down to 1.4 BARg (20 psig) via a
separate regulator, or it may be taken from a
downstream point of the final regulation station,
before the meter.
All pressure piping including filters, heat

exchanger, regulators, etc., are protected from
over-pressure by safety relief valves, or dual
main/monitor-type regulators with slam-shuts.
All relief valves are vented to atmosphere
through a common discharge pipe to safe
location.

The discharge pipe serves as a manifold for venting gas coming from relief valve discharge, as well as for manual
drain valves. All piping and tubing are either fabricated and joined using threaded and welded connections, or using
tube compression fittings. They are designed, manufactured, and tested in accordance with code requirements.
For PRM part numbers and assembly diagrams, refer to the Engineering Drawings section of this document package.
6.1.1. Regulators identification

In multiple stages regulation the first stage typically employs spring operated, high-pressure
regulators, to decrease the pressure to an appropriate level for the second stage. These regulators
can be pilot-operated, in parallel or individually.
If applicable, the second (and third) stage of regulation employs pilot operated regulators, which
decrease the pressure to the desired discharge pressure. These pilot operated regulators are installed
in either a "Standby Monitor" configuration, or a "Working Monitor" configuration.
6.1.2. Standby monitor

In a "Standby Monitor" installation (see below), the downstream pilot operated regulator is set at a higher pressure,
and only functions in the event of a failure of the upstream pilot operated regulator. The set-point of the standby
monitor should be slightly higher than the operating regulator (i.e. 5%).
6.1.3. Working monitor
In a "Working Monitor" installation (see below), both pilot operated regulators are working to reduce pressure in a
two- stage sequence. The 1st stage regulator (upstream) will be set significantly higher than the 2nd stage regulator
(downstream) regulator. The specific characteristics and parts of your system can be found in Engineering Drawings
sections of this document package.

6.1.4. Pilot operated regulator set-point adjustment

Pilot operated regulators are installed in series in either a working or
standby configuration. For "Standby Monitor" note the pressure
differential to ensure the monitored line is installed correctly.
Pilot operated regulators are set by turning the hex knob on the top of
the pilot under the cap. If the unit has an over-pressure slam shut valve,
first set it by adjusting the knob on the front of the slam shut valve,
monitoring the gauge installed on the monitored line to the set pressure
as listed on the P&ID
For "Standby Monitor" configuration, set the monitor regulator first

(downstream & higher set pressure) by adjusting the knob on the pilot using the gauge installed on the monitored
line to the set pressure listed on the P&ID. Then set the operating regulator (upstream & lower set pressure) in the
same fashion as the first to the set pressure listed on the P&ID.
For "Working Monitor" configuration, set the 1st stage regulator first (upstream & higher set pressure) by adjusting
the black knob on the pilot using the gauge installed between the regulators to the set pressure listed on the P&ID.
Then set the 2nd stage regulator (downstream & lower set pressure) in the same fashion using the gauge installed
after the downstream regulator to the set pressure listed on the P&ID.
Note: The pictures on this page are for illustration purposes only. Actual parts and specifications may vary.

6.2. Heating control module - HCM

The inlet gas line to the HCM comes
from the PRM. The gas flowing to the
HCM may pass through inlet valves,
which are used to isolate the HCM.
A regulator and a pressure gauge are

installed at the boiler inlet to ensure
correct supply pressure.
Consult the boiler manual for

requirements. A gas bleed line is
installed after the regulator.
The HCM water flows through the

inlet past a low flow switch. At this
point a check valve and regulator
provide an inlet for additional water to
the system.
The water flows to the air separator tank, which includes a vent at the top, removing any air trapped from the
system.
From the tank the water passes through a strainer to remove debris, before reaching the pump. The water is
pumped into the boiler. A flow-meter installed at the water discharge side monitors the flow. After heating, the
water can be re-circulated (looped) via the 3-way valve, or directed to the PRM.
The water flows through galvanized piping and fittings, or marine-type hose. All pipe and hose fittings are threaded.
Gas line pipes use compression fittings. They are designed, manufactured, and tested in accordance with code
requirements.
For HCM part numbers and assembly diagrams, refer to the OEM Documentation.
Note: The pictures on this page are for illustration purposes only. Actual parts and specifications may vary.

6.3. PRM/HCM Control module – Description

The PRS operating logic is controlled by a programmable logic controller (PLC). In the case of a standalone PRS
system the PLC is mounted in the PRS control panel, or the HCM.
If the PRS is part of a large site system with a compressor, the control may be incorporated into the compressing
system PLC, and not an independent PLC. Regardless of its location, the PLC starts and stops the PRS, continuously
monitors its status, and indicates alarm conditions.
The PRS status is monitored by various sensors for pressure, temperature, and flow. All sensors, switches, motors,
and solenoid valves used in the PRS are wired using methods approved for the specific installation area
classification.
All PRS modules have an ESD (Emergency Shut Down) system that is hard-wired, and incorporates red mushroom
pushbuttons in key locations.
This system safely shuts down and isolates the PRS from the gas supply.
Online/Offline switches are located on the HCM panel, and on the control panel. Both switches must be in the online
position for the PRS to function automatically.
WARNING!
The Online/Offline switches should NOT be used as a disconnect switches. They do not
make it safe to work on the PRS. To perform maintenance safely, turn off and lock out
the main circuit breaker in the electrical panel.

7. Installation
The following information is provided only as a general guide for equipment installation. Considering that the
installation procedures vary greatly with each equipment configuration and local characteristics, it is essential to
employ the services of a technician experienced in the installation of such equipment, and with full knowledge of
local codes and regulations. Contact your local IMW representative for further information.
All site electrical schematics and general configuration drawings are found in the Installation section of this
documentation package.
7.1. PRM/HCM installation
7.1.1. General considerations

Ensure that the following pre-conditions are present before proceeding with the installation
• The site layout design MUST meet local codes for classification of hazardous areas;
• The system must have adequate space around the skid for easy maintenance access. Please refer to IMW
General Arrangement drawings for skid dimensions;
• The inlet gas pipe should be routed so that access to the unit is not obstructed;
7.1.2. Physical placement and securing

NOTE: Before removing the system from its transport vehicle or container, inspect its general post-shipment
condition, and that the packing list matches what is found. If you notice signs of shipping damage or
components missing, DO NOT proceed with the installation. Contact your supervisor for insurance and other
legal proceedings that may be necessary, as well as repairs that may need to be executed, before the installation
is allowed to continue.
Continuing the installation process without notification may void the warranty.
Danger zone
Due to the nature of the deployment procedures, including the equipment weight, and
high energy of the latent supplies, there is an elevated risk of accidents during the
installation procedures. Wear full protective gear at all times.
The PRM is skid mounted, open design and suitable for outdoor mounting on a small concrete pad.
The PRM is rated Class I, Division 2 (Zone 2), Group D.
The HCM is also skid mounted and requires a small weather protection shelter with concrete pad.
The boiler must be installed such that gas ignition system components are protected from water (dripping, spraying,
rain, etc.) during operation and service.

The HCM is rated non-hazardous, but must be located at least 4.5m (15 feet) from the PRM, (if mounted separately)
or as required by local installation codes.
As it is appropriately named, the foundation is the basis of a good operation and long equipment life. Poorly
prepared foundations lead to excessive vibration, causing premature equipment failure, risk of accidents, and may
void the warranty. Once the skid is secure to the foundation, the chassis must be bonded to a sufficient electrical
ground source (grounded), according to local regulations.
Sufficient supply of pressurized clean water, as well as unobstructed drainage for water coming from the relief
valves, must be available to the HCM at all times.
7.1.3. Concrete foundation

The PRM and HCM must be provided with independent flat and level concrete foundation at least as large as the
plan dimensions of each skid (if mounted separately). For the PRS a margin of 24 inches (61cm) around all sides is
recommended for service. If delivered as a single frame, use these dimensions for the entire skid.
The following table shows recommended area for service:
Boiler Sides Rear Top Front (service)

Model in mm in mm in mm in mm
AAE 6 153 6 153 36 915 40 1016
SG 2 51 2 51 24 610 24 610
Concrete pad thickness and reinforcement must be determined according to the weight distribution of the skid(s)
and the underlying soil properties. All relevant local building codes should be met for this purpose.
For the concrete pad design, the gross equipment weight can be considered to be evenly distributed over the plan
area. Poorly prepared foundations may cause premature equipment failure, and may void the warranty. Consult a
local civil engineer.
7.1.4. Skid bolt down

The PRM and HCM skids have provisions for bolt down via bolt down lugs, with locations as shown in the general
arrangement drawing.
Ensure that ALL bolt-down lugs are located and used. Use "Hilti®-type concrete fasteners", or equivalent
compression or epoxy concrete anchors are recommended for installation.
The concrete equipment foundations should be flat and level in accordance with standard machine mounting
practices.
If the concrete foundation pads are sufficiently level, the skids can be secured to the pads without any need for
additional shimming or grouting.

7.1.5. HCM shelter provisions

Ensure clearance of at least 152mm (6 inches) from boiler draft hood and the flue pipe, in any direction.
Sufficient air supply must be provided to the boiler. Air openings to the HCM room provide air for combustion, flue
gas dilution, and ventilation, regardless whether the air is taken from inside or outside. The air opening size and
location (as well as other air supply and venting considerations) must conform to all applicable local codes, laws,
regulations, and ordinances.
NOTE: The HCM room must never be under a negative pressure.
Always provide air openings sized not only to the dimensions required for the total input of all fuel-fired appliances
in the boiler space, but also to handle the air movement rate of any exhaust fans or air movers using air from the
building or space. The venting terminations must always be kept clear of obstructions (i.e. snow, ice, etc.). Louvers
and grilles used in the air supply and ventilation system should be kept clear of any dust, dirt, or debris blocking
proper air flow.
7.1.6. HCM vent provisions

The gas fitter/installer is responsible for providing a suitable vent of adequate draft capacity, in good usable
condition. Interference with the air supply to the boiler is prohibited.
Vent installation and type of gas vent or vent connector must follow all applicable local codes, laws, regulations, and
ordinances.
For boiler connections to gas vents or chimneys, vent installations shall be in accordance with Venting of
Equipment, of the National Fuel Gas Code, Part 7, ANSI Z223.1, or Venting Systems and Air Supply for Appliances,
Section 7, of the CAN/CGA B149 Installation Codes. These codes can be obtained at the CSA Website. Outside
Canada, consult your regional regulatory agency.
The venting shall be supported as required by applicable code(s). Horizontal runs shall slope upward not less than ¼
inch per foot (21 mm/m) from the boiler to the vent terminal.
The unit must be installed with the factory supplied draft hood in place. The draft hood is a safety device designed to
control chimney drafts that might affect combustion, or blow out the pilot. The draft hood supplied with the boiler
must not be altered. The minimum skirt height as indicated on the draft hood must be maintained.
Vent connectors serving the boiler must not be connected into any portion of mechanical draft systems operating
under positive pressure.

7.1.7. Automatic vent damper (if applicable)

All boilers with an input of 300,000 Btu/h, or lower, are supplied with an automatic vent damper.
The following instructions must be observed:
• The automatic vent damper should be installed at the top of the factory supplied draft hood.
• The venting system must be arranged so that only the boiler is served by the automatic vent damper with
which it was supplied.
• Connect the wiring harness from the boiler to the automatic vent damper, as indicated on the supplied
wiring drawings.
• The automatic vent damper position indicator should be clearly visible after installation.
• A minimum clearance of no less than 155 mm (6 inches) must be maintained between the automatic vent
damper device and combustible construction. Provision must be made for service access to the automatic
vent damper.
• The automatic vent damper must be in the open position when the boiler's main burner is operating.
• For orientation other than vertical, refer to automatic vent damper installation instructions.
NOTE: No modifications to the automatic vent damper are permitted, and may void the warranty.
7.1.8. Vent terminal information

The minimum distance from the termination of a vent terminal to adjacent public walkways, adjacent buildings,
open-able windows, and building openings shall be not less than those values specified in the National Fuel Gas
Code, ANSI Z223.1 and/or CAN/CGA Installation Codes. These codes can be obtained at the CSA Website. Outside
Canada, consult your regional regulatory agency.
For proper operation, the vent terminal must be kept free of snow and other debris at all times.
To prevent discoloration and degradation of building materials by flue gases and flue gas condensation, ensure that
the vent terminal is installed clear of nearby obstacles. In all cases, installation shall be in accordance with local
code.
Maintain a minimum clearance of 1.20 m (4 feet) horizontally. In no case the clearance around the electric meters,
gas meters, regulators, and relief equipment should be less than 1.20 m (4 feet).
Burn Hazard
All vent ducts and their adjacent components are extremely hot.
Do not touch them without proper protection.

7.1.9. Pressure relief valve and discharge pipe

A pressure relief valve is supplied as standard equipment. The pressure relief valve is extra protection against
damage that could be caused by malfunctioning controls, or excessive water pressure. If a pressure relief valve is not
used, the warranty is void. The pressure relief valve is installed on the boiler outlet with its spindle vertical.
A discharge pipe should be used. The discharge pipe outlet should be positioned over a suitable drain, and arranged
so that there is no danger of scalding (steam burns).
The discharge pipe must pitch down from the valve and should be no smaller than the outlet of the valve. The end of
the discharge pipe should not be concealed or threaded and should be protected from freezing. Extensive runs,
traps, or bends could reduce the capacity of the pressure relief valve.
No valve of any type should be installed between the pressure relief valve and unit or in the discharge pipe. The
pressure relief valve is a code requirement. Field installation of the relief valve must be consistent with the
ANSI/ASME Boiler and Pressure Vessel Code, Section IV.
Explosion Hazard
The pressure relief valve discharges pressurized hot water which can turn into steam.
Steam exiting the discharge outlet can expand explosively in any direction. Always
maintain a safe distance from the discharge pipe outlet.
7.1.10. Site piping

To realize the full capacity of the PRM, the entire system installation must be carefully planned to provide adequate
flow capacity to the upstream gas supply connected to the PRM.
In mobile storage pay particular attention to piping, valves, and manifold design connecting to the storage. Install
only high pressure pipe lines from de-fuelling posts to the PRM.
The water supply and return piping between the HCM and PRM must be adequately sized for the flow rate
requirements. The water pressure drop between the PRM and HCM should not exceed 2 to 4 psi. The pipe
diameters must be up-sized for long piping runs, in order to avoid drop in pressure.
An adequate sized fuel supply line from the PRM to the HCM must also be provided. This line must be capable of
retaining pressure at full loads.
7.1.11. Cathodic Protection

Buried gas supply piping must have cathodic protection according to the local installation codes. This requires the
use of insulating flanges at the entrance and exit of the pipe from the ground, and sacrificial anodes buried at
intervals, as required by the local codes.

7.1.12. Isolation Valves

Isolation valves are supplied at each inlet and outlet of both the PRM and the HCM. These valves are required for
lockout and must not be removed.
7.1.13. Boiler operating requirements

Avoid unnecessary replenishment of fluid/water. It may result in air entering the system causing corrosion. Also,
minerals dissolved in the water supply precipitate when heated, depositing predominantly in the heat exchanger.
Do not draw water from the heating system for cleaning, flushing, etc.
The boiler is designed as a closed-loop system. It is not intended for open systems, such as heating pool water, or
systems where water is constantly replenished. Operating the boiler as an open system may result in premature
failure of the heat exchanger, and may void the warranty.
Heating systems with low temperature return water may cause flue gas moisture to condense on the boiler heat
transfer surfaces, causing corrosion and restricting flue gas flow, resulting in premature failure.
Low temperature return water may also overcool the flue gases, resulting in reduced vent suction. These are natural
phenomena, independent of the boiler design. As a guide to avoiding such conditions, it is imperative that the return
water temperature remains above 57°C (135°F).
7.1.14. Area electrical classifications

All electrical equipment on the PRM skid is designed for minimum Class I, Division 2 (Zone 2), Group D hazardous
locations.
NOTE: Please reference the PRM & HCM or panel nameplate for the actual hazardous area classification as the
divisions and classifications may change depending on specific design criteria.
All electrical equipment within Class I, Division 2 (Zone 2), Group D areas must be designed and wired accordingly.
Non-incendive safe wiring is used on the PRM skid to connect to pressure and/or temperature sensors. Under
normal operating conditions, this prevents any sparking, which might ignite gas.
Areas sufficiently far from gas containing equipment (3 meters/10 feet - 5 meters/15 ft in the USA), are considered
non-hazardous, and safe for locating equipment that is not rated for a Class I, Division 2 environment.
Intrinsically safe wiring is present to the online/offline switch sensors and to some pressure sensors located in
Division 1 areas. They use intrinsically safe barriers to limit current circulating in the wiring. This configuration
prevents sparking that could otherwise ignite gas.
For precise area classifications refer to CSA publication CAN/CSA B149.1 Natural Gas and Propane Installation codes.
These codes can be obtained at the CSA Website. Outside Canada, consult your regional regulatory agency.

Electrical Hazard
Component substitution may compromise suitability of equipment for operation in a
hazardous location.
Do not replace any electrical component in a classified area unless power has been
disconnected and effectively locked-out.
7.1.15. Electrical control panel installation

Applicable electrical controls (including those for the PRM) with NEMA 12, 4 or 3R electrical panel enclosures must
be located remotely in a non-hazardous area.
NEMA 4 and 3R panels are weatherproof and suitable for outdoor mounting. NEMA 4 and 3R panels subjected to
cold winter temperatures should be equipped with thermostatically controlled space heaters.
NEMA 12 panels should be mounted in a secure weatherproof building, or special kiosk. If the electrical control
panel is not skid mounted, it should be bolted to the floor foundation, or wall mounted.
7.1.16. Electrical field wiring connections

The installer must complete electrical connections from the remote electrical controls to the PRM & HCM. Electrical
connections can be made with solid wire and conduit, or armoured flexible cable conduit. If using buried cabling,
electrical runs must be buried 0.6 to 1.0 meters below grade. Connections at PRM & HCM are made with conduit
and seals, or connection glands at the appropriate junction boxes on the equipment.
Required electrical cable, junction box port sizes, and electrical termination details are provided in the equipment
electrical installation drawings found in the Engineering Drawings section of this document package.
7.1.17. Blocked vent and flame roll-out safety switches (if applicable)
All boilers with an input of 300,000 Btu/h and under are equipped with blocked vent and flame roll out safety
switches. These safety switches are installed in the clip provided on the draft hood (alternate 1), or are mounted
with screws (alternate 2).
The blocked vent safety switch is prewired at the factory either directly to the boiler controls (Alternate 1 and 2), or
through a wiring harness for boilers with an automatic vent damper (Alternate 3).
If the vent is blocked by soot or corrosion, the boiler shuts down. Keep the vent free of obstructions.

Poisoning Hazard
The shutting down of the boiler by either the “blocked” vent, or the “flame roll- out”
safety switch may indicate that carbon monoxide is improperly venting into the
premises. As a result, the boiler MUST be serviced by a qualified person immediately.
WARNING: CARBON MONOXIDE IS A LETHAL, COLOURLESS, AND ODOURLESS GAS!
8. Start-up and commissioning
8.1. Start-up preparation

After completing the Pressure Reduction System (PRS) installation in accordance with all applicable codes,
regulations, and manufacturer's instructions, the station is ready for start-up and commissioning.
The following recommended start-up procedure is to be performed by qualified technical personnel only, with
experience in the start-up procedures and operation of newly installed CNG refuelling equipment. This procedure is
generic, and may have to be modified to suit specific sites and equipment.
Explosion Hazard
Before allowing any inlet supply gas to enter the newly installed system and high
pressure piping assemblies, the entire system and piping system must be purged of air,
using nitrogen (see instructions below).
Failure to do so may result in an explosion inside the compressor or piping system!
8.2. Start-up procedures

These procedures describe the first-run sequence for both the Pressure Reduction System (PRS) and the Heating
Control Module (HCM). It must be followed every time the system has stopped for maintenance, or otherwise
disconnected from the main gas supply line.
Warning: If it is confirmed or suspected that air entered any lines, purge procedures must be executed again.
8.2.1. Pre-start-up check list (first operation) - Gas

Prior to purging, verify that all required installation work is complete with the following check list:
1. Close all PRS discharge isolation ball valves; ⃝
2. Open the isolation ball valve into the priority, ESD and/or other panels; ⃝
3. All skids (PRM, HCM) and auxiliary equipment are positioned and
anchored to their respective concrete slab; ⃝
4. Inlet gas piping is installed and cathodically protected, if necessary,

with the final gas connection complete; ⃝
5. Each inlet isolation ball valve must be closed isolating downstream piping; ⃝

6. All dispenser piping is installed with filters and isolation valves; ⃝
8.2.2. PRM Piping Nitrogen Purge

1. Close all drain valves. Ensure that the gas inlet and discharge isolation ball
valves are closed; ⃝
2. With the PLC programmer, force open any actuated inlet valves after the
manual inlet valve if applicable; ⃝
3. Disconnect the inlet filter drain line and connect a nitrogen gas
bottle/regulator/valve combination to the drain of the inlet filter; ⃝
4. Open the N2 gas bottle and set regulator to a pressure of 60 psig maximum; ⃝
5. Open the N2 gas valve and allow N2 gas to fill the PRM; ⃝
6. Once a position pressure has been reached, open the drain valve and allow
the gas to exhaust through the drain lines for a time; ⃝
7. Close the valve at the N2 bottle and disconnect the N2 supply. Reconnect the
drain line to inlet filter drain; ⃝
8. Open the drain valve on the vent header and allow the nitrogen to drain
from the piping system. Once the nitrogen is drained, immediately close
all drain valves; ⃝
8.2.3. Pre-start-up check list – Water

1. Determine the volume of the entire 50/50 ratio of water-glycol mix; ⃝
NOTE: The Water/Glycol mix is a requirement. Do not operate with water only!
2. Open all valves and ensure that vents are unobstructed; ⃝
3. Fill the system with the correct volume of Glycol; ⃝
4. Complete the system with water, bleeding at the pump; ⃝
5. Force the pump to circulate, monitoring the water circuit pressure; ⃝
6. Bleed air from HXs, and any other high point; ⃝
7. Add water to compensate the bleeds; ⃝
8. Repeat steps 6 to 8 above until the pressure stabilizes; ⃝
9. Adjust the booster and steps 6 to 9, as required. ⃝

9. Operation
9.1. Initial operation
The boiler must be lit and ready to heat water. If the boiler is not ready consult the Boiler Manufacturer Manual in
Appendix 1 – OEM Documentation, for the appropriate lighting instructions.
The Human Machine Interface (HMI) is a multi-function, touch-screen panel that adapts to the immediate operating
needs. The top bar always displays the system’s current status.
To initiate operation, place the Online/Offline switch (main panel) in the “Offline” position, and then press the
“Reset” button.
If all of the alarms are cleared the status bar will indicate “OFFLINE”.
If an alarm condition exists, the alarm banner pops up to describe the

alarm condition. Correct the cause for the alarm, and press reset
again to clear the alarm condition. Once the alarms have been
cleared and the status bar indicates “Offline”, the system is ready to
operate.
Place the Online/Offline switch to the “Online” position.
The main menu shows the PRS serial number, site name (if available), and date/time.
By touching any of the corresponding function keys, the screen changes to display the appropriate information.
Some function keys are repetitive throughout the various screens. These are navigation and information functions,
and have no direct influence in system operation. These function keys are:
• MAIN MENU returns to main menu.
• LANGUAGE toggles between English and a different language (optional).
• LAMP TEST illuminates all lamps on the control cabinet and PRS.
• METRIC/IMPERIAL toggles between metric units (BAR, °C) and imperial (PSI, °F)

9.2. Running operation

When the PRS is first placed in the Online mode, the system completes
a “Warm up” cycle that sends a “request for heat” signal to the boiler,
it then places the diverter valve at a fixed position of 100% open. The
amount of time the system warms up is based on the customer
setpoint. The default value is 180 sec.
Once warm-up is complete the system is declared “Ready”. It

automatically controls the gas outlet temperature by varying the water
temperature to the heat exchanger using the water diverter valve and
the boiler water temperature.
The diverter valve controls the amount of hot water passing through the heat exchanger by diverting a portion of
the flow back to the pump. The amount of flow that is diverted back to the pump is determined by a PID control
algorithm that ensures that operating gas temperature at discharge is maintained between 10-40˚C. (50-104 ˚F)
On some models, dual diverter valves or pumps are used for redundancy. On these models, the diverter valves and
pumps are selected manually using the selector switches on the control panel, and placing the manual ball valves in
the appropriate position for the selected device.
9.3. Running conditions

The following events occur during normal operation, i.e. the online selector is at the “Online” position, and there are
no alarms:
• The inlet valve remains open when there are no alarms;

• The boiler power is “ON” when there are no alarms;
• The boiler heat is turned “ON” while the boiler power is on;
• The pump runs continuously, after being placed in “Offline” (default: 60sec);
• The water diverter valve is preset to open during warm-up (default: 100%), after which the valve position is
controlled by the PLC;
• If the gas temp falls below a preset value (default: 10°C /50°F), the water diverter valve is opened fully
(100%). This action sends all of the available hot water to the heat exchanger;
• If the gas temp rises above a preset value (default: 40°C /104°F), the water diverter valve closes (0%). This
action prevents any hot water from reaching the heat exchanger;
• If the water diverter valve is closed for a preset period (default: 5 min), the boiler heating shuts off.
The boiler self-regulates the water temperature by turning the heat on/off. However, it automatically shuts off by
any of the following events:
• Pump O/L warning

• Low water flow warning

• Gas temperature high warning

• Water diverter open too long.
9.4. Alarms and warnings

When any of the PRS sensors signal a fault condition to the PLC, the PRS shuts down. A red alarm indicator lights up
on the control panel and at the PRS skid.
After the PLC registers an alarm, the PRS cannot operate until the fault condition has been corrected, and the PRS
control panel has been reset. Even if the alarm condition clears itself, the indicator lights remain illuminated until
the control panel is manually reset.
To reset all alarms, first ensure that all alarm conditions have been corrected. Then, push the green reset button on
the control panel. The PRS returns to normal running operation. If the alarm conditions have not been properly
cleared, the alarm reappears on the screen.
NOTE 1: Warnings are not alarms; they are displayed on the screen, and may stop certain parts of the system.
However, they do not stop the entire PRS system.
NOTE 2: The low gas temperature alarms are ignored during warm-up mode. This allows the boiler time to raise the
water temperature above the alarm value so operation can resume.
9.4.1. Alarms list
ITEM CAUSE DEVICE DEFAULT DELAY
PLC I/O error Internal PLC error or fault na na na
Pressure transmitter out of range or

Inlet/Outlet PT fault 4-20 ma na na
broken wire
Thermocouple out of range or broken
Gas temp fault (Discharge or HX) Thermocouple na na
wire
23F (-5C) 5 min
Gas temp low (Discharge) Gas Temp is lower than Setpoint Thermocouple
-4F (-15C) 20 sec
59F (15C) 5 min
Gas temp low (HX) Gas Temp is lower than Setpoint Thermocouple
32F (0C) 20 sec
PRV failure (High pressure) Outlet pressure rises above the Setpoint PT 170psi 2 sec
High inlet pressure Inlet pressure above the setpoint PT 3750 0.5 sec
One or more PTS not scaled Some pressure transmitter not scaled PT na na
ESD pushed ESD button is pushed switch na 0.5 sec

na = not applicable

9.4.2. Warnings list
ITEM CAUSE DEVICE DEFAULT DELAY
Warning PLC math error Internal PLC math error PLC na 1 sec
Too much motor current or O/L in OFF

Warning pump #1 O/L O/L on device na
position
Warning low water flow Low or no water flow (while running) flow switch na 60 sec
Warning gas temp low If Gas Temp is lower than Setpoint Thermocouple 32F (0C) 1 sec
Warning gas temp high If Gas Temp is higher than Setpoint Thermocouple 131F (55C) 1 sec
na = not applicable
9.5. Alarm History

The alarm history screen shows the last 20 alarms that have occurred.
They are stored in the PLC, time date stamped, and cannot be cleared.
Use the “Next Screen” and “Previous Screen” buttons to scroll through
the entire list.
The newest alarm is placed at the top of page one forcing the oldest
alarm out of the list.
9.6. Stopping operation

To stop the PRS system, place any of the Online/Offline switches in the “Offline” position. The boiler shuts down,
and the inlet valve closes immediately. The pump runs for a preset time before stopping.
System alarms also stop the entire PRS system. However, these alarms cause the pump to stop immediately.

9.7. Setpoints
WARNING!
Incorrect setpoint adjustment may result in erratic operation, that may lead to damage
to the system. Only trained and authorized personnel should be allowed to alter
setpoints!
When the “SET POINT SCREENS” button is pressed, the password

screen is displayed.
By touching the password entry box, a numeric keypad is displayed.

Enter the appropriate password, and press the return arrow.
When the correct password is entered, the first Setpoints page is

shown
9.7.1. Altering setpoints

NOTE: Setpoints are only displayed and entered in imperial units (PSI, °F).
Use the “NEXT SCREEN” and “PREVIOUS SCREEN” buttons to navigate through the setpoints screens.
To alter setpoints:
• Touch the desired setpoint. The numeric keypad is displayed;
• Enter the new value. The new value must be within the
minimum and maximum values displayed;
• Press the Return arrow to confirm. Once the new value is

displayed, it has been accepted;
• Go to the NEXT SCREEN until the last screen is displayed. This

screen gives the option to load all the factory default settings
“YES LOAD DEFAULT SETPOINTS” button loads all factory default

setpoints, overwriting all setpoints previously changed with the value
shown in the default column.
The SETPOINT column shows the value that the PLC is currently using.
The DEFAULT column is the factory set value.

9.8. Misc screen

The Misc (miscellaneous) screen is used to change time, date, and
screen display parameters.
To change the date, select the MISC button on the main screen and
enter the desired values, followed by the return arrow. The display and
the PLC synchronize within five seconds.
The PROGRAM SCREEN button shuts down the system control screen
and opens its own setup functions.
NOTE: Do not attempt to change these parameters unless you are fully qualified to do so. It may result in loss of
screen formatting. Factory reset may be necessary.

10. Optional Equipment
10.1. Voltage monitor

A voltage monitor can be installed as part of the control system to ensure the PRS electrical modules are supplied
with the correct voltage for their operation.
The voltage monitor is set to trigger an alarm when the line voltage rises above or falls below 10% of the rated
voltage. It also monitors phase loss and phase rotation.
In the event of a drop in voltage, phase loss, or a change in phase rotation:
• A system alarm or warning is generated, and the PRS may stop (depending on the unit);
• The operator must ensure that the system voltage is back to normal before the system is restarted. The
Voltage/Phase monitor may need to be reset manually (depending on the unit);
• The operator must acknowledge the alarm by pressing the reset button, returning the system to online
condition (if it has stopped).
NOTE: Severe damage can occur if a voltage or phase event happens while the monitor is not present, has been
removed, or by-passed.
10.2. Uninterrupted power supply (UPS)

A UPS is recommended for the PLC, ESD circuit and dispenser electronics. If not purchased from IMW, any installed
UPS must meet IMW specifications.
NOTE: Do not connect additional devices to the UPS without consulting an IMW representative.
The UPS is used to provide clean power to all PLC and Dispenser circuitry. In the event of a power failure, it prevents
these devices from powering down unexpectedly.
10.2.1. UPS minimum requirements

Any customer supplied UPS shall meet or exceed the following requirements:
Input Output
Power (per system specs) ex: 1500 KVAa Voltage Regulation: ±2% (117.6-122.4/215.6-224.4 Vac
Frequency: 50Hz or 60Hz Output waveform: Sine wave
Frequency window: 45-65 Hz Freq. Regulation: ±0.25 Hz (battery or free run mode)
Synchronization window: ±3 Hz Distortion-TDH: <3% Linear, <5% Non-linear load
Power factor (cos φ): 0.97 Transient Response: 4% (100% Load change)
Overload capacity: 125% for 1 min/150% 10 sec
Crest factor: 3:1
Efficiency: >86%

Customer supplied UPS systems should also provide protection against:
• Output Short Circuit
• Abnormal Voltage
• Abnormal Frequency
• I/O Noise
• I/O Spike and Transient
• Complete Battery Drain
10.2.2. UPS installation

IMW control panels are designed to support the UPS systems, and are supplied with standard interconnection
terminals to allow for ease of installation.
A typical IMW control panel has a vertical row of Red terminals, including
• terminals labelled ‘100’, ‘N’, ‘X1’, and ‘X2’;
• label beside terminals ‘100’ and ‘N’ that reads “From UPS”;
• label beside ‘X1’ and ‘X2’ that reads “To UPS”.
If the input power for the UPS is from the IMW control panel, the terminals used are ‘X1’ and ‘X2’.
If the power is from an external supply, the customer is required to ensure that regardless of the input voltage, the
output voltage is 120 volts. The output of the UPS is to be terminated to terminals ‘100’ and ‘N’.
If the IMW control panel comes with a receptacle and an electrical cord on the side of the enclosure, the UPS is to be
plugged in directly.
NOTE: If the UPS is supplied by IMW, the UPS manufacturer recommends charging it for 4 hours before operation.
10.2.3. Additional options

Other option available for the Pressure Reduction system are:
• Redundant system
• Seismic switch
• Excess gas flow alarm
• Redundant pump motor
• Redundant diverter valves (manual switchover)
• HMS gas detector
• Thermocouple or 4-20mA temperature reading

11. Maintenance and Troubleshooting
11.1. Elements of maintenance interest
11.1.1. Inlet Filter

NOTE: All filter recommendation, and piping installation assume the supply of Sweet, Dry, and Clean Natural Gas.
Low quality or contaminated natural gas may rapidly damage the filter elements and other components. An
additional inlet separation filter may be necessary.
The inlet filter provides particulate removal from the inlet gas, and it also functions as a condensate trap. It requires
draining every 2 weeks.
To drain the inlet filter:
1. Shut down the system;
2. Open the inlet filter drain valve on the bottom of the filter housing, or vent header and allow the collected
condensates to drain into the vent header;
3. Close the inlet filter drain valve, and restart the compressor.
After commissioning, the filter should be changed according to the following schedule:
• First phase: 25 hours after start-up and commission of the compressor station;
• Second phase: every 50 hours of operation until 475 hours after start-up;
• Third phase: every 1000 hours as part of a scheduled maintenance and service program.
11.1.2. Pressure transmitters

Pressure transmitters are installed at the inlet and discharge of the PRM. Both transmit signals to the PLC, which
compares the signal from a pressure transmitter with both a high and a low pressure setpoint, shutting down the
PRS when the setpoints are exceeded.
It is recommended that all set points be tested for correct PRS shutdown periodically, according to Preventive
Maintenance Schedule.
11.1.3. Shell and tube heat exchanger

The vessel transfers heat from one fluid to another. This is achieved by increasing the effective contact area
between the natural gas and coolant. The result is one fluid is heated (gas) while the other fluid (water/glycol
mixture) is cooled. The shell of the heat exchangers should be flushed with fresh water and provided with a new
50/50 water/glycol mixture annually to prevent corrosion and provide lubrication to the vessels’ components.

11.1.4. Boiler
The boiler heats a 50/50 mixture water/glycol, running in a closed-loop circuit to the shell & tube heat exchanger(s).
The boiler also has an external water supply inlet to automatically replenish the system, from the water/glycol
makeup system compensating it for losses due to evaporation and small leaks. The water pressure at this point
should always be between 12 and 15 PSI. Water can also be added at this point using a hand pump and drum.
For detailed maintenance instructions, consult the OEM Documentation, included in this documentation package
11.1.5. Relief valves

Relief valves provide over-pressure protection to pressurized components of the PRS such as piping, valves, filters
and fittings.
Even though the system is protected by pressure switches at all its stages, in the unlikely event that an interlock
sensor or electrical control fails, the relief valves safely vent the over pressurized gas. Each relief valve discharge
port is piped either directly, or via a vent header, to the atmosphere, venting the gas at a safe elevation.
Relief valves are adjusted and tested to vent gas at a precise pressure setting as determined by the maximum
working pressures of the components it is protecting.
WARNING!
It is recommended that all pressure relief valves be removed and tested EVERY THREE
YEARS by a certified relief valve testing shop, as per local safety codes and standards.
If a valve fails to discharge at its rated pressure, it MUST be serviced or replaced.
Danger!
While a relief valve has been removed:
• Do not start the system!
• Keep the all areas of the control system locked out!
• Do not plug or obstruct a relieve valve port!
11.1.6. Vent header

A vent header is a manifold that may conduct some relief valve discharges for safe venting into atmosphere. The
bottom of vent header is also a common collector for all condensates drained from filters. The vent header should
be drained every 2 weeks by opening the drain ball valve located at the base of the header.
11.1.7. Low water flow cut-off switch

The low water flow cut-off switch is mounted on the HCM, before the pump and monitors water flow. In the case of
a heating system failure causing insufficient water flow, the boiler is safely shutdown though a PLC-generated alarm
condition.

The low water flow cut-off switch should be checked for correct boiler shutdown operation every 1000 operating
hours. In some locations an additional low water level switch is added to the system, to comply with local code.
11.1.8. Strainer
The strainer ensures that no solids enter the pump. The strainer must be opened and cleaned at every 2 weeks.
11.1.9. Pump
The pump circulates a water/glycol mixture (at 50/50ratio) in a closed-loop circuit to the shell & tube heat
exchanger(s). The rotation direction needs to be verified when first starting or pump replacement. Ensure that it
rotates in the same direction as indicate by the arrow on its body.
It is required that the pump motor have its bearings lubricated as part of a scheduled maintenance and service
program. Lubrication intervals vary according to the running conditions that the motor is subject to. The ideal
running conditions would be described as clean environment (no dust), ambient temperature, less than 40°C, and a
maximum of 8 running hours per day. If the existing running conditions are more severe, the lubrication frequency
should be increased, according to the table below.
Severity Hours/day Ambient Temperature Atmospheric Contamination
Standard 8 40°C Clean, Little Corrosion
Severe 16+ 50°C Moderate Dirt, Corrosion
Extreme 16+ >50°C Severe Dirt, Abrasive Dust, Corrosion,
11.2. Preventive maintenance (PM) schedule

500 hours or 6
1500 hours or
2000 hours or
10000 hours
20000 hours
40000 hours
1000 hours
3000 hours
5000 hours
Bi-weekly
Recommended Maintenance Items

Monthly
months
1 year
1year
System walk-around ●
Make up tank water-level indicator check ●

Strainer ●
Drain filters ●
Vent header drain ●
Water pump ●
Low water shut-off valve ●

500 hours or 6
1500 hours or
2000 hours or
10000 hours
20000 hours
40000 hours
1000 hours
3000 hours
5000 hours
Bi-weekly
Recommended Maintenance Items
Monthly
months
1 year
1year
Change filter elements ●
Flush/replace coolant ●
Remove/test relief valves ●
11.3. Torque recommendation
• Heat Exchanger : 108 NM (80 lb-ft);

• All other bolts should follow the General Torque Specification for size and material;
• OEM equipment and parts, such as regulators, valves and flanges, should follow the manufacturer’s specification
11.4. Maintenance records template

Use the Maintenance Log template in the following page to record all maintenance intervention performed and
parts replaces on each systems. Keep all records on site, with easy access to management, and all maintenance and
safety personnel. It is highly recommended that an updated copy be kept in a remote site.

Maintenance Log
Equipment Equipment
name: serial number:
Date Service performed/Parts replaced Executed by: Approved by:

11.5. Parts ordering procedure
11.5.1. Parts under warranty

In order to ship parts under warranty, IMW needs to validate the information regarding the parts to be replaced,
and the equipment where the parts are used. When contacting IMW, please have the following information ready:
• Part name (or description) and part number (see drawings and schematics);
• Equipment serial number;
• Equipment hour meter reading;
• Brief description stating how the part failed, and/or why the part needs to be replaced;
• A clear and complete address to where the new part is to be shipped;
• The name and phone number of at least one person fully aware of the warranty claim.
An email with this information to the Aftermarket department (aftermarket@imw.ca) suffices to start the process.
After IMW confirms the warranty claim, it may dispatch a replacement part immediately.
In case the warranty claim is in doubt, but the situation is considered urgent, IMW may ship a replacement
immediately. However, IMW requires that the customer issues a Purchase Order.
IMW may also request that the old part be shipped to IMW Headquarters, or one of its offices or agents. In this case,
IMW generates a RMA (Return Material Authorization) number, and provides clear instructions to where, and how
to ship the part.
NOTE: Do not ship the part until you have received the RMA number!
Only after evaluating the part received, a full warranty may be granted.
If the old part is not received within 30 days, or if the part received is deemed not a warranty case, an invoice is
generated charging for the part shipped.
This process is the same for one or more parts, as long as the process is initiated as a single claim.

11.5.2. Parts out of warranty

The procedure for shipping purchased replacement parts is similar to the procedure above.
When contacting IMW, please have the following information ready:
• Part name (or description) and part number (see drawings and schematics);
• Equipment serial number;
• Equipment hour meter reading (Optional. For statistical purposes only);
• A clear and complete address to where the new part is to be shipped;
• The name and phone number of at least one person fully aware of the order.
An email with this information to the Aftermarket department (aftermarket@imw.ca) suffices to start the process.
Upon receiving the request, IMW generates a formal quote, and provide an estimated delivery date.
Once the quote is confirmed by a Purchase Order, the part is scheduled for shipping, and the contact is informed of
all shipping details.
It may be possible that a faulty part, such as a CPU or a valve, may be refurbished by IMW, or OEM manufacturer,
and thus have a core value. In this case, IMW requests the return of the old part, analyse its condition, and issue a
credit to the customer equal to the estimated core value.
IMW evaluation results are final and non negotiable.
11.5.3. Technical support and field service calls

Technical support response and costs vary greatly from region to region.
Please contact IMW Industries’ Aftermarket Department (aftermarket@imw.ca) for information regarding services
in your area.


IMW PRESSURE REDUCTION SYSTEM MANUAL
INSTALLATION DOCUMENT LIST
The installation section of the IMW Pressure Reduction System manual consists mainly of drawings used for site
layout and design, as well as piping schematics. Included in this section will also be any useful procedures related
to or preceding installation.
As with the Main Document List, this document lists the complete set of items that comprise the IMW Pressure
Reduction System manual installation appendix.
Document Document Number Revision Pages

PRESSURE REDUCTION MODULE GENERAL
700784 B 5
ARRANGEMENT
HEATING CONTROL MODULE GENERAL
700785 B 4
ARRANGEMENT
PRS FLOW P&ID 700334 B 1
PRS FLOW P&ID PARTS LIST 700335 D 3
DECANTING POST GENERAL ARRANGEMENT 700373 B 2
FO-AD-2010-007 Rev.0 Page 1 of 1

This page is intentionally left blank.

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DOCUMENT #: 700335
DESCRIPTION: PRESSURE REDUCING SYSTEM GAS FLOW 4000PSIG 2000NM3/HR
P&ID DRAWING #: 700334
REVISION HISTORY
REV DATE REFERENCE DCR# BY / CK
A 2012/10/23 FIRST RELEASE N/A DJS/GSL
B 2012/11/20 ADDED: REF# 041, 103, 532, 732, 733, 734; N/A DJS/BJN
C 2013/01/03 EDITED:
EDITED: REF#
REF# 14
532(WAS
(WAS329528), REF# 710 & 711
"NOT REQUIRED") N/A DJS/GSL
D 2013/01/14 EDITED: REF# 009 (WAS 332197) N/A DJS/BJN
Revisions indicated in Italics
REF PART # DESCRIPTION MFG NAME
001 324629 VALVE BALL CS 2WAY 1.500FNPT 5000 PSI AOP
002 332207 VALVE NEEDLE CS 0.250MNPT - 0.250FNPT ALCO
003 329798 VALVE BALL SS 1.500FNPT 6000PSIG W.ACT ECLIPSE
004 601014 VALVE SOLENOID 2WAY SAE6 120V 60HZ 5000PSI JEFFERSON
005 329761 VALVE RELIEF 2.00FNPT-2.00FNPT 700PSIG MERCER
009 331877 VALVE RELIEF 0.75MNPT-1.00FNPT 115 PSI MERCER
010 331878 VALVE RELIEF 0.75MNPT-1.00FNPT 150 PSI MERCER
011 329634 RUPTURE DISC 1.00 UT 3000# 175PSIG BURST FIKE
012 307515 VALVE BALL BRASS 5044A 0.250FNPT CLS600 TOYO
020 339583 VALVE RELIEF 174A 2WAY 0.750FNPT @60PSI WATTS
021 331687 AIR SEPARATOR VENT 0.125MNPT WATTS
022 329773 VALVE GLOBE BRONZE 1.500FNPT 125# WOG TOYO
027 339582 AIR SEPARATOR 2.00FNPT WATTS
028A 329537 VALVE BRONZE 3WAY 1.50FNPT NO ACT SIEMENS
028B 350756 VALVE ACTUATOR 24VAC 4-20mA 0-10VDC NSR SIEMENS
029 332243 VALVE SOL 3WAY 120V-50/60HZ ASCO
030 321580 VALVE CHECK SS C4L 0.250T-MNPT@6000PSIG PARKER
031 331681 VALVE CHECK BRONZE UNION 0.500FNPT WATTS
037 328324 VALVE BALL CS 3.000FLG 150# CE TRIAC
039 N/A NOT REQUIRED N/A
700335 Page 1 of 3
101 326076 FILTER CLSC 1.500FNPT 5000PSIG 1MIC PARKER
102 330652 STRAINER IRON 2.000 NPT 20 MESH 400PSI MCMASTER CARR
201 203213-05-16N COOLER SHELL&TUBE GW5000-5X8X71 IMW
202 203213-05-16N COOLER SHELL&TUBE GW5000-5X8X71 IMW
203 330640 BOILER 600000/480000 BTU 120V/60HZ ALLIED ENGINEERING
204 339584 PUMP WATER 2.00/1.00FNPT C/W MOTOR ADAPT SUMMIT
205 601071 EXPANSION TANK HYDRONIC 6.0 GAL 0.500 MNPT FLEXCON
206 329772 FLOWMETER WATER 15-150 GPM 1.500MNPT MCMASTER CARR
207 310535 SWITCH FLOW FS4 7.4A@120VAC 1.0NPT 150LB MCDONNEL MILLER
208 210067 PIPE SPOOL 4.000 SCH80 9.5LG IMW
301 329753 REGULATOR 1.0FNPT 6000PSI TESCOM
302 601075 REGULATOR PILOT SS 0.250FNPT 10000PSIG 5-800PSIG TESCOM
303 329754 REGULATOR 2.000FNPT 600# MOONEY
304 329754 REGULATOR 2.000FNPT 600# MOONEY
305 322291 REGULATOR PILOT 4000-80 PSIG 0.250FNPT (SET TO 100PSIG) KIMRAY
306 324196 REGULATOR FUEL 0.500NPT C/W RELIEF VALVE FISHER
307 327581 REGULATOR PRES 627 1.000FNPT 5-20PSI FISHER
308 328358 REGULATOR PRESSURE BRASS 0.500FNPT WATTS
401 339585 HANDPUMP - PAIL & DRUM MCMASTER CARR
501 322459 GAUGE PRES 2.5IN DIAL 345 BAR/5000 PSIG WIKA
502 322454 GAUGE PRES 2.5IN DIAL 14 BAR/200PSIG WIKA
504 322457 GAUGE PRES 2.5IN DIAL 70 BAR/ 1000 PSIG WIKA
505 322457 GAUGE PRES 2.5IN DIAL 70 BAR/ 1000 PSIG WIKA
508 339586 GAUGE PRES 2.5IN DIAL 0-30 IN-H2O WIKA
509 319790 GAUGE PRES 0-60PSI 2.5IN WIKA
520 333455 TRANSMITTER PRES 0-5000 PSIG 0.250 MNPT ASCO
521 329744 TRANSMITTER PRES 0-200 PSIG 0.250MNPT ASCO
530 309747 THERMOCOUPLE TYPE J 300IN LEADS 0.250 WIKA
601 339503 MOTOR 3HP 3600RPM 460-3-60 182JM TEFC WEG
701 312894 PIPE SA-106 GR.B 1.5NPS X SCHXXS UNIFIED ALLOYS
703 303747 TUBE SS SA-213 T316/316L 0.250 X 0.035 SANDVIK
705 312548 TUBE SS SA-213 T316 1.000 X 0.120 SANDVIK
709 311968 PIPE SA-106 GR.B 2NPS X SCH80 UNIFIED ALLOYS
710 304320 TUBE SS SA-213 T316 0.500 X 0.065 UNIFIED ALLOYS
711 304320 TUBE SS SA-213 T316 0.500 X 0.065 UNIFIED ALLOYS
712 311519 PIPE SA-106 GR.B 3.000NPS X SCH80 COMCO
713 601569 HOSE AUTOMOTIVE 1.000IN ID 80PSIG -40F TO 250F NEWLINE
714 601569 HOSE AUTOMOTIVE 1.000IN ID 80PSIG -40F TO 250F NEWLINE
715 303479 PIPE A-53 GALV 1.500 X SCH40 UNIFIED ALLOYS
700335 Page 2 of 3
721 311446 PIPE SA-106 GR.B 1.5NPS X SCH40 UNIFIED ALLOYS
731 301313 PIPE BL CS SA-53 0.750 X SCH40 AJ FORSYTH
732 303747 TUBE SS SA-213 T316/316L 0.250 X 0.035 UNIFIED ALLOYS
733 311968 PIPE SA-106 GR.B 2.0NPS X SCH80 UNIFIED ALLOYS
736 303479 PIPE A-53 GALV 2NPS X SCH40 UNIFIED ALLOYS
737 303479 PIPE A-53 GALV 2NPS X SCH40 UNIFIED ALLOYS
SETPOINT PRESSURE
A 650 PSIG
B 58 PSIG
C 65 PSIG
D 20 PSIG
E 100 PSIG
F 14 IN H2O COLUMN (0.5 PSIG)
G 10 PSIG
DESIGN DESIGN TEST TEST PRV

ZONE
PRESSURE TEMPERATURE PRESSURE SETPOINT
1 4000 PSIG -20F TO 130F 4800 PSIG 4850 PSIG
6 20 PSIG -20F TO 130F 24 PSIG 26PSIG
7 <15 PSIG -20F TO 130F N/A N/A
700335 Page 3 of 3
IMW PRESSURE TEST REPORT
Test Standard CSA B51
UNIT UNDER TEST (UUT) DATA TEST REQUIREMENTS
Work Order ID 1006622 Type (media) Pneumatic (air)

Part ID 203213-05-16N Design Pressure (PSIG) 100
Part Description Cooler Shell&Tube GW5000-5x8x71 Test Pressure (PSIG) 110
Sequence ID 40 (Approx. 7.58 BAR, 758.42 kPa)
Serial # 1006622-3 Shell Duration (minutes) 15
Drawing ID (incl Rev.) 203213-05 Rev H
PRESSURE GAUGE(S) USED

Serial # Description Range Accuracy +/- Cal. Due
PRIMARY
IMW-778 Gauge, Pressure 0 to 300 PSIG 3 PSIG 2013/09/01
SECONDARY (If Used)
TEST DATA
MDMT (see drawing) Test Commenced On (YYYY/MM/DD) 2013/04/22
-20
PART DESCRIPTION HEAT NUMBER PART DESCRIPTION HEAT NUMBER HT# VERIFICATION
Shell 1131974
All Heat Numbers
Tube 216900
Verified (Certs on File).
Tube Sheet MM11103196 (2)
Couplers 3753 (2) Checked By:
tgoody
Metal Temp WATER TEMP >70F (ASME SECT I)
( > MDMT +30 F)
Test Commenced By tgoody Witnessed By N/A
Employee # 695 Employee # N/A
* Pressure increased incrementally prior to Test Steps below.
Actual Readings (PSIG)
Test Steps Target (PSIG) Primary Gauge Secondary Gauge Time
(1) Pressure On 100 110 6:30 AM
(2) Pressure Off 110 110 7:00 AM
Test Completed By tgoody Witnessed By N/A

AI Acceptance (when req'd): Date:
NOTES
Welded by RS & DM
RESULTS
Pressure gauge(s) used were calibrated and traceable to National and/or International Standards.
IMW hereby certifies the UUT stated above was tested with the following results:
P Valid Pressure Gauge(s) Used
P Heat Numbers Verified
P Test Pressure Attained
P Test Pressure Maintained
P Test Duration Attained
P Pneumatic (air) Test Type Confirmed Report Completed By: tgoody
Report Date: 2013/04/22
PASS
FO-QC-2003-051 Rev.6 Page 1 of 1
Work Order ID 1006622 Type (media) Hydrostatic (water)

Serial # 1006622-3 Tube Duration (minutes) 30

PRIMARY
SECONDARY (If Used)
TEST DATA
-20
Shell 1131974 Bolts IK651
All Heat Numbers
Tube 216900
Cover Plates H0727 (2) tgoody
( > MDMT +30 F)

(1) Pressure On 6,500 6500 10:55 AM
(2) Pressure Off 6,500 6500 11:25 AM

NOTES
Welded by DM
RESULTS
P Hydrostatic (water) Test Type Confirmed Report Completed By: tgoody
PASS
Work Order ID 1006622 Type (media) Pneumatic (air)

Serial # 1006622-4 Shell Duration (minutes) 15

PRIMARY
SECONDARY (If Used)
TEST DATA
-20
Shell 1131974
All Heat Numbers
Tube 216900
tgoody
( > MDMT +30 F)
* Pressure increased incrementally prior to Test Steps below.
(1) Pressure On 100 110 6:30 AM
(2) Pressure Off 110 110 7:00 AM

NOTES
Welded by RS & DM
RESULTS
P Pneumatic (air) Test Type Confirmed Report Completed By: tgoody
PASS
Work Order ID 1006622 Type (media) Hydrostatic (water)

Serial # 1006622-4 Tube Duration (minutes) 30

PRIMARY
SECONDARY (If Used)
TEST DATA
-20
Shell 1131974 Bolts IK651
All Heat Numbers
Tube 216900
Cover Plates H0727 (2) tgoody
( > MDMT +30 F)

(1) Pressure On 6,500 6500 10:55 AM
(2) Pressure Off 6,500 6500 11:25 AM

NOTES
Welded by DM
RESULTS
P Hydrostatic (water) Test Type Confirmed Report Completed By: tgoody
PASS
12 11 10 9 8 7 6 5 4 3 2 1
C IMW INDUSTRIES LTD. 2011/09/20 REVISION HISTORY
DO NOT USE AS THE BASIS
H H
FOR MANUFACTURE OR SALE OF REV. DATE BY CK. DCR# REFERENCE
APPARATUS WITHOUT
PERMISSION.
B 2005/07/21 DVL N/A N/A SEE 3213-00REV.DOC
2 C 2006/10/30 BVK N/A N/A ADDED NAMEPLATES
30°
D 2006/11/03 BVK N/A N/A CHANGED PIPE LENGTH FROM 66.5"
E 2008/10/02 GL N/A N/A ADDED THREE 0.5" CS PLUGS
F 2009/08/26 AS GL 1519 ADDED BEVEL DETAIL TO COUPLER. CHANGED
WELDING PROCEDURE FROM IMW-002A TO IMW-030
G 2011/06/06 ERL EDL N/A UPDATED DESIGN CODE TO 2010
UPDATED TEXT BLOCK TO THE LATEST VERSION
H 2011/09/20 BJN DJS N/A CORRECTED SHCS SIZE IN BOM FROM 0.25 TO 0.50
1/16"
IMW-015
G 0.10 TYP.
G
DETAIL D
SCALE 1 : 1
SECTION C-C
DETAIL B
SCALE 2 : 1
75.880
+.000
TUBE LENGTH 70.940
-.020
F F
SHELL LENGTH 66.625±.010
NOTES: TORQUE FOR BOLTS

WELD NAMEPLATE IMW-030
11
STAMP HEAT NUMBER 2 PLCS = 80 FT-LBS
4.625 ON NAMEPLATE
D 8
1/4
10
2.500 9.065 9.500 TYP. C 4 1
A
3 E 6
E 5
E
7.875
7
C A
WELD B
D 12 2 X 4"
3 ITEM 12
CLOSE TO WATER PORT NOTES :
D
H 2 PLCS SECTION A-A STAMP
DESIGN SPECIFICATIONS: "MAWP 5000PSIG"
1.125 TUBE SIDE "YEAR OF MANUFACTURING"
DRILL ON SHELL 1 3/4" • MAWP: 5000 PSIG @ 400 F "SERIAL #"
2 PLACES • MDMT: -20 F @ 5000 PSIG AT BOTH ENDS
• SERVICE: SWEET DRY NATURAL GAS
IMW-030 • HIGHEST DEW POINT OF NATURAL GAS: -37 F
2 PLCS • CORROSION ALLOWANCE: NONE
• PWHT: NONE
1/4 • VOLUME: 214.35 IN^3 = 0.124 FT^3
39° SHELL SIDE
• MAWP: 100 PSIG @ 400 F
C •
•
MDMT: -20 F @ 100 PSIG
COOLANT: 50%WATER AND 50%GLYCOL C
• VOLUME: 1332.89 IN^3 = 0.77 FT^3
APPLICABLE DESIGN CODES:
• ASME SECTION VIII, DIVISION 1, BOILER AND PRESSURE VESSEL CERTIFIED BY
DETAIL E CODE 2010 LATEST ADDENDA IMW INDUSTRIES LTD.
SCALE 1 : 1 • CSA B51-09, BOILER, PRESSURE VESSEL, AND PRESSURE PIPING
2 PLCS CODE. MAWP 5000 PSI AT 400 F
MDMT -20 F AT 5000 PSI
NDE REQUIREMENT: PRESSURE TEST TO ASME SECTION VIII MFG. SERIAL NO. _________
• TUBE SIDE YEAR BUILT ______________
• HYDROSTATICALLY TEST AT 6500 PSIG
• (1.3 TIMES DESIGN PRESSURE)
• SHELL SIDE CRN: EXPIRES

B • HYDROSTATICALLY TEST AT 130 PSIG B
ITEM PART • (1.3 TIMES DESIGN PRESSURE)
NO. QTY NUMBER DESCRIPTION SIZE UOM SPECIFICATION WEIGHT
• NO RADIOGRAPHIC EXAMINATION REQUIRED
1 6 203213-03 BAFFLE PLATE n/a EA CS A36 0.6
2 4 301753 BAR RD 0.25 DIA X 66.1 LG IN CS A36 0.9 CANADIAN REGISTRATION NUMBER
3 2 321861 COOLER TUBE NAMEPLATES n/a EA n/a 0.1 • THIS FITTING DESIGN HAS BEEN REGISTERED AND GIVEN A DIMENSIONING & TOLERANCING PER IMW Industries Ltd.
Chilliwack, BC, Canada
CRN (SEE NAMEPLATE). ASME Y14.5M-1994. U.S.O.:
4 1 321879 COOLER TUBE NAMEPLATES n/a EA n/a 0.242 • ANY REVISIONS TO THE PRESSURE PARTS REQUIRE THE DESIGN
5 2 203213-04 COVER PLATE 8.0 DIA X 2.625 LG EA CS SA-105 24.3 TITLE
TO BE RESUBMITTED FOR APPROVAL.
6 6 317784 PLUG HOLLOW HEX CS 0.5 MNPT n/a EA PARKER# 01HP-8-S 0.1 • SEE NAMEPLATE FOR EXPIRATION DATE. GAS-TO-WATER COOLER
7
8
2
1
305572
311508
ORING 2-240 V90D
PIPE, SCS
n/a
5" X SCH 40 X 66 5/8 LG
EA
IN
VITON
SA-106 GR.B
0.01
81.0 UNITS INCHES X/X ±1/16 GW5000-5X8X71
FILE. NO.
FINISH 64 MICRO IN. .X ±.1 REF. STANDARD SIZE REV
9 2 308782 COUPLING HALF SA-105 1.000NPT 3000# 1 NPT 3000# EA SA-105 0.44 203213-05
A 10
11
40
2
318899
203213-01
TUBE
TUBE SHEET
0.50 OD X 0.095 WALL X 70 15/16 LG
8.0 DIA X 2.625 LG
IN
EA
CS SA-179
CS SA-105
2.4
24.3
INNER RADI .03
.03
MAX. .XX
MIN. .XXX
±.01
±.005
DR. KH
CK. DVL
2004/09/27
2011/06/06 D DWG. NO.
MRP ID 203213-05
H A
OUTER
12 48 303663 SHCS CS 0.500-20UNF-3A X 2.500 ASME n/a EA n/a 0.024 H EDGE X 45° ANGLES ±.5 AP. SCALE 1:3 WEIGHT 285.7 LBS SHEET 1 / 1
12 11 10 9 8 7 6 5 4 3 2 1
CERTIFICATE OF COMPLIANCE
Customer Name: IMW INDUSTRIES LTD

43676 PROGRESS WAY CHILLIWACK BC V2R 0C3 CANADA
Customer PO Number: PO1016321
Item Description: Qty: (1) 81-12151V37G11 ¾" MALE X 1" FEMALE

Series 8100 Serial Number(s) 905776
Set @ 150 psi Customer PN
Capacity SCFM Air 557
Repair Kit Number: 11V1G11
Mercer Valve Sales Order Number: AQ243

Mercer Valve Job Order Number: AQ243-1
Valve Setting Instructions:

Set Pressure: 150 psi
Set Pressure Tolerance: 3%
Test Medium: Air
This certifies that the valves purchased on the above sales order number were built per section VIII, Division 1 of
ASME boiler and pressure vessel code as indicated by the UV on the nameplate.
__________________________________________________________________ 05/07/2013
Certified Individual
Quality Control

Manual PRS Imw

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ISO 9001 43676 Progress Way Tel: (604) 795-9491

Chilliwack Fax: (604) 792-3806

IMW-PRS PRESSURE REDUCTION SYSTEM

PRM S/N: WC1007909 HCM S/N WC1005735

Customer name: CEDP TRUJILLO Installation date: JUNE 2013

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CM-2012-002-Rev. 0 June 2012

IMW-PRS Release Date: June 2012 Page 2 of 48

IMW-PRS Release Date: June 2012 Page 3 of 48

6.1.2. Standby monitor .............................................................................................................................. 20

IMW-PRS Release Date: June 2012 Page 4 of 48

9.2. Running operation ....................................................................................................................................... 34

IMW-PRS Release Date: June 2012 Page 5 of 48

11.5.2. Parts out of warranty....................................................................................................................... 47

IMW-PRS Release Date: June 2012 Page 6 of 48

I. Document Revision History

If information beyond the scope of this manual is required, please contact:

or one of its representatives.

IMW-PRS Release Date: June 2012 Page 7 of 48

V. Safe Work Practices

VI. Roles and Responsibilities of the Qualified Maintenance Personnel

VII. Roles and Responsibilities of the Operation Personnel

IMW-PRS Release Date: June 2012 Page 8 of 48

1. Who we are and what we do...

Welcome to IMW Full in-house capabilities…

…CNG refuelling systems have earned IMW a Innovative…

IMW-PRS Release Date: June 2012 Page 9 of 48

IMW Industries IMW Industries Inc.

IMW Compressors (Shanghai) Co., Ltd. IMW CNG Bangladesh Ltd.

IMW Colombia Ltda.

IMW-PRS Release Date: June 2012 Page 10 of 48

NG Equipment & Systems Limited. Spectron SDN BHD

PAKISTAN CZECH REPUBLIC

Allied Engineering Services Limited Bonett Bohemia, a.s.

IMW-PRS Release Date: June 2012 Page 11 of 48

IMW-PRS Release Date: June 2012 Page 12 of 48

5. General safety information and emergency response procedures

5.2. Visual communication

5.2.1. Danger Symbols

Elevated risk of death or injure in case No cigarette, lighter, matches, or other

No open flame, such as blow torches A fully operational fire extinguisher

IMW-PRS Release Date: June 2012 Page 13 of 48

5.2.2. Warning Symbols

Risk of explosion, or uncontrolled Risk of catching, crushing, or severing

5.2.3. Safety equipment symbols

Apply individual padlock protection Wear protective gloves against cuts,

IMW-PRS Release Date: June 2012 Page 14 of 48

5.3. Safety instructions

5.3.1. Local safety regulations

5.3.2. Entering a hazardous environment

5.3.3. Lock-out procedure

IMW-PRS Release Date: June 2012 Page 15 of 48

5.3.4. Opening the electrical cabinet

5.3.5. Safety remarks regarding operation

IMW-PRS Release Date: June 2012 Page 16 of 48

5.3.6. Safety remarks in case of gas leaks

5.3.7. Arc flash and arc blast hazards

Personal exposure to an arc flash frequently results in a variety of serious

IMW-PRS Release Date: June 2012 Page 17 of 48

5.3.8. Arc Flash Hazard Analyses

For detailed information on how to conduct an Arc Flash test, consult:

Canadian Standards Association - Occupational Health and Safety Program (CSA-OHS)

5060 Spectrum Way

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