中集圣达因车载供气系统交流资料

张家港中集圣达因低温装备有限公司
Low temperature insulated gas cylinders

450L 侧置 500L 侧置 500L 双后置

1000L 后置 1350L 后置 1000L 双 +450L 侧

三瓶组
 Working principle of LNG on-board gas supply system

The inner tank is designed with a two-stage safety valve to protect

against overpressure. In the case of overpressure, first open the main safety
valve, the opening pressure is 1.72Mpa (cylinder working pressure
1.45Mpa), 1.90MPa (cylinder working pressure 1.59Mpa), the opening
pressure of the secondary safety valve is 2.41MPa (350psi), the set pressure
is higher than the main safety valve, in the main safety valve failure or
failure, the secondary safety valve works, so that the cylinder use to ensure
safety.
 Working principle of LNG on-board gas supply system

• The protection of the shell under internal overpressure conditions is

achieved by a ring-shaped vacuum plug, if a large amount of leakage
occurs in the inner tank (resulting in an ultra-high jacket pressure), the
vacuum plug will automatically spring off the pressure relief; When a
micro-leak of the inner tank leads to a decrease or failure of the
thermal insulation capacity, the cylinder may "sweat" or frost the shell.
Of course, frost or condensation at the end of the pipe connected to
the cylinder is normal.

• The design filling rate of the cylinder is 87% filling rate, the cylinder is
equipped with an anti-overfilling device in the inner tank, excessive
filling can be avoided during the filling process, the filling pipeline is
equipped with a one-way valve to ensure that LNG can only flow in
one direction to the inside of the cylinder, the liquid outlet pipeline is
equipped with a flow valve, when the external pipeline breaks or a
large amount of leakage, the flow valve will limit the liquid leakage in
the cylinder.
 Working principle of LNG on-board gas supply system

Inner Interlayer insulation housing

Level sensors tank

Assign headers Inner tank pipeline

LNG vehicle gas cylinder is a kind of low-temperature insulation pressure vessel, suitable for
use in normal ambient temperature, designed with a double-layer (vacuum) structure, the
inner tank is used to store liquefied natural gas, and there are multiple layers of thermal
insulation material wrapped on its outer wall, with super thermal insulation performance, while
the jacket (the space between the two layers of containers) is pumped into a high vacuum,
together to form a good thermal insulation system.
 LNG Working principle of on-board gas supply system
2.LNG Vehicle gas cylinder piping system
Leak alarm
Transmitter
Protective ring
Pressure gauge

Main safety valve Liquid outlet valve

Secondary safety valve
Drain tube

Level gauge terminal posts

Inlet check valve

Economy valv

Venting valve Filling hose

Return airpipe
Booster valve

Filling seat
Return air seat

Buffer tank pressure gauge

3.LNG on-board gas supply system equipment

a.Regulator valve - stabilizes the gas

pressure after the regulator valve at the
set pressure.
Pressure adjustment range: 100~200psi,
factory set pressure 125psi (about
0.86Mpa), actual can be adjusted
according to the needs of engine use.

b.Vaporizer - uses the method of

exchanging heat with the engine
circulating cooling water to gasify the
cryogenic liquid (LNG) to heat up the
temperature to meet the purpose of
engine use. Design pressure 2.42Mpa.
c.Supercharger
Water bath supercharger - integrated
with the gasifier, the cryogenic liquid
(LNG) is gasified by exchanging heat
with the engine circulating cooling
water to increase the gas phase
pressure in the cylinder.
Design pressure 2.42Mpa.

Air-temperature supercharger - uses 空温式增压器

the method of exchanging heat with
air to vaporize the cryogenic liquid
(LNG) to achieve the purpose of
increasing the gas phase pressure in
the cylinder.
d.Buffer tank – provides air supply
cushioning to prevent insufficient air
supply when the vehicle is started at
rapid gas or low temperatures.
Design pressure 2.42Mpa.
Buffer tank
e.Aeration components

Filling seat - equipment for

connecting a gas gun and filling the
cylinder with cryogenic liquid,
diameter DN25.

Return gas seat - equipment

connected to the return air gun to
return the high-pressure gas in the
cylinder to the storage tank, through
diameter DN10. Aeration components
• f.Level indicator - LNG vehicle bottle level
gauge adopts capacitive level gauge, and the
displayed data changes with the height of
LNG liquid level.

Filling seat Return gas seat

 Filling operation specifications
1.Hot bottle filling
Generally, we refer to cylinders before the first filling of cryogenic liquids
and more than two weeks of downtime as "hot cylinders".
Because its inner tank is an ambient temperature, direct filling will
vaporize a large amount of cryogenic liquid and cause unnecessary
so it needs to be filled according to the following filling procedure:
 First, fill the bottle with about 20~30L of liquefied natural gas, let
stand for 1-2 minutes, and cool the inner tank of the cylinder during
the gasification and pressurization process of liquefied natural gas in
the bottle;
 When the pressure in the bottle reaches the normal working pressure,
the system is tested for leakage;
 After reducing the pressure in the bottle by opening the venting
valve, the normal filling procedure can be followed.
Filling operation specifications

2.Conventional filling

• Conventional filling of automotive LNG is done via

a separate hose. First connect the gas filling gun
with the liquid filling port, and then start the filling
switch of the gas dispenser, the liquefied natural gas
enters the inner tank of the cylinder through the
connecting hose, and the liquefied natural gas
retained in the bottle is re-liquefied through the
liquid inlet pipe at the top of the inner tank to
reduce the pressure in the bottle, so that the filling
is completed quickly.
 Filling operation specifications
The filling valve is a check valve, which automatically opens under pressure
when filling liquid, without manual switching, when the filling reaches the rated
amount, the filling automatically stops and the check valve closes.

3.Return gas filling

The return gas filling of automotive LNG is done through two hoses. First
connect the gas filling gun with the liquid filling port, and then connect the
return gas gun with the return air port, open the venting valve, start the gas
dispenser filling switch, the liquefied natural gas will enter the cylinder liner
through the connecting hose, and the natural gas inside the cylinder will
return to the gas filling station storage tank through the return port,
reducing the pressure in the cylinder and making the filling quickly complete.
 Caution!
1.LNG mixed with air or oxygen can form a detonating gas that burns in
case of fire, so LNG must be led to a safe place through pipelines for
discharge.
2.The pressurization speed of the cylinder is related to the amount of liquid
in the cylinder, when there is more liquid in the cylinder, the pressurization
speed is relatively fast, and when the liquid is less than 20%, the
pressurization speed will be very slow.
3.Before gassing, carefully check whether there is leakage in each
connecting part, if there is, the filling must be stopped, and the filling can
be carried out after tightening without leakage.
4.A cylinder filled with LNG has a rapid pressure rise that may cause the
safety valve to open, so it should be used as soon as possible and long
storage is prohibited.
 Daily use and maintenance of gas cylinders

1.Cylinders for daily use

 Before driving, it is necessary to check whether the fixed between the cylinder and
the bracket, the gas supply device and the girder is firm, whether all the gas pipe
connections are leaking, and whether the sensor joints are loose.
 After the inspection, slowly open the discharge valve. When opening the valve, twist
the valve back once after opening it fully to prevent the valve from being stuck. After
stopping, close the self-boosting valve first, and then close the outlet valve and the
venting valve can be in the normally open state. If the shutdown time exceeds two
days, the venting valve needs to be closed.
 When starting the engine, turn on the ignition key, pause for five seconds and then
start the engine to ensure that the gas line can be filled with gas, and idle for 30
seconds after the engine starts, check whether the oil pressure and water
temperature are normal.
 Daily use and maintenance of gas cylinders

2.Precautions for gas system maintenance

 Regular maintenance and repair of gas systems should be carried out in
professional maintenance enterprises.
 When maintaining the vehicle, it is strictly forbidden to knock or collide with
gas cylinders, pipelines and various valve bodies.
 When troubleshooting the gas supply system, all bottle valves must be
closed, pipeline pressure relief is carried out, and repair operations are
strictly prohibited under pressure.
 All kinds of joints should be strictly checked for integrity. High-pressure
pipelines and ferrule fittings can only be replaced with new ones, and are
not allowed to be reused. After maintenance, a gas detector or foaming
liquid should be used for leakage testing.
 Daily use and maintenance of gas cylinders

• After disassembling and inspecting the pipeline and

various joints, the pipeline must be blown to prevent
impurities from entering the gas pipeline (which will
cause the exhaust of the safety valve to not return to
position).
 Common faults of gas cylinders and treatment methods
Symptom Cause analysis solution

1.The set pressure of the refueling Adjust the refueling equipment to the
The pressure in the cylinder is equipment is too high appropriate pressure
too high when filling
2.The cylinder is filled for the first Normal phenomenon, return to the
time trachea to vent
Filling is carried out according to the
1.Overfilling
rated amount
The pressure in the cylinder is Normally, the cylinder is pre-cooled
2.Hot bottle filling
raised too quickly after filling when filling
Repair the vacuum or return to our
3.Loss of vacuum
company for repair
1.The setting pressure of the saving Adjust the saving valve to the
valve is too high appropriate pressure
2.The saving valve is out of order
Repair and replace the saving valve
and damaged
The pressure in the cylinder is 3.The booster system opens, and
too high when the vehicle is used the regulator sets the pressure too Lower the regulator set pressure or
replace the regulator
high or fails
Repair the vacuum or return
4.Loss of vacuum
to our company for repair
 Common faults of gas cylinders and treatment methods

1.The saver valve setting pressure
is too low
2.The saving valve is out of order
and damaged
The pressure in the cylinder is
too low when the vehicle is 3.Gas phase pipelines and fittings
used leakage
Adjust the saving valve to the
appropriate pressure
Repair and replace the saving valve
Repair pipes and fietters. And leak
detection again

Turn on the booster system, and

4.The boost system is not turned on open the booster valve and venting
valve at the same time
 Common faults of gas cylinders and treatment methods
Symptom cc
1.Check whether the cylinder
The supply pressure is too high pressure is normal
or too low 2.The regulator sets the pressure
improperly
1.The cylinder liquid has run out
2.The outlet valve is not open
No gas supply 3.The solenoid valve is not open or
malfunctioning
4.The vaporizer does not vaporize
properly
1.The cylinder is not used for a long
time after it is filled with liquid
The safety valve opens
normally
2.Loss of vacuum
Safety valve low pressure
1.The safety valve fails
opening (below set pressure)
1.The safety valve spring cannot be
The safety valve does not returned to the seat
close after opening
2.The safety valve fails
solution
Adjust the regulator to the
appropriate pressure
refuleing
Open the liquid discharge valve
Check whether the power supply is
normal and whether the solenoid
valve is intact
Check whether the vaporizer
circulating water is normal
Start the vehicle running, or open
the vent valve to relieve pressure
Repair the vacuum or return to our
company for repair
Replace the safety valve
Douse warm water and gently tap
the valve body
Replace the safety valve
 Common faults of gas cylinders and treatment methods
Symptom Cause analysis solution
The pressure gauge is
1.The pressure gauge is damaged Replace the pressure gauge
unresponsive
1.When the cylinder is used, sweating may
occur in the front and rear heads, and it is
Normal use
normal if the pressure rise rate is not
obvious
2.The ambient temperature is too low, the
Normal
Sweat or frost on the air humidity is high, especially on rainy days
bottle
Check the leakage point and then
3.There may be a leak in the joint repair it according to the operating
procedures
4.If the pressure rise rate is obvious, it is a Stop using and return to our
vacuum failure company for repair
The level gauge is not Check whether the signal and
1.Line connection failure
displayed power cord connections are reliable
Check the transmitter status light, if
1.Transmitter failure
it is solid, it needs to be replaced
2.Conductor short-circuit or isotonic water at Check the wires, dry the moisture,
The level gauge shows
the link and reset the connections
abnormalities
Check the transmitter status light,
3.The capacitive sensor in the cylinder is
such as blinking rapidly, to check if
faulty
the cable is open
 Safety protection and operation

1 、 Security
 Keep LNG equipment away from flames or electric sparks ；
 Fireworks are not allowed in areas where LNG equipment is repaired, filled
and stored ；
 When working on equipment filled with LNG, goggles, face shields, and
insulated gloves are required ；
 When disassembling parts for maintenance, the LNG cylinder needs to be
emptied, depressurized and replaced ；
 All personnel entering the site of LNG cylinders should wear fireproof and
anti-static work clothes and work shoes ；
 When the cylinder is not in use, the driver should close all valves ；
 Emergency response plan

3.When the inner container is accidentally leaked:

At this time, the inner container is in a state of excess pressure due to
internal liquid leakage, which will cause and cause an accident, and the
liquid in the bottle should be carefully discharged as soon as possible,
and if conditions permit, the damaged bottle should be transferred to a
place without open flame, flammable materials and pedestrians for
emergency treatment.
4.When the valve is frozen:
If the valve is frozen, it should be thawed with clean oil-free warm water
or hot nitrogen before operation. Do not strike with a hammer or other
object.