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Inspection Guidelines for CNG & LPG Vehicle Conversions
 

Inspection Guidelines for CNG & LPG Vehicle Conversions

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This Clean Cities webinar is an overview of the processes of converting a vehicle to CNG & LPG and the need to use a qualified installer. We had speakers from the Gas Technology Institute in Illinois ...

This Clean Cities webinar is an overview of the processes of converting a vehicle to CNG & LPG and the need to use a qualified installer. We had speakers from the Gas Technology Institute in Illinois who will gave an overview of the guidelines to inspect CNG and LPG vehicle conversions. Also, American Power Group, ROUSH CleanTech, and Barnes, Inc. covererd the conversion kits and processes of installing them.

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    Inspection Guidelines for CNG & LPG Vehicle Conversions Inspection Guidelines for CNG & LPG Vehicle Conversions Presentation Transcript

    • CNG and LPG Vehicle Purchasing Inspection Guidelines > January 2014
    • Statement of Purpose Agenda • Consumer expectations for CNG and LPG vehicle purchases • Inspection requirements for CNG and LPG vehicles • Finding a qualified individual to conduct safety inspections • Training for inspectors • Inspection checklist 2
    • Converted CNG Vehicle Purchase Guidance: Do some research. 1. US EPA and CARB certified conversion kits and engine platforms are allowable under current federal regulation. • NGVA List: http://www.ngvc.org/pdfs/availablevehiclesandconversions_130920_f inal.pdf • EPA Website: Certified Clean Alternative Fuel Conversion Systems http://www.epa.gov/otaq/consumer/fuels/altfuels/documents/certifiedconversions.xls 2. Converters need to be approved by kit manufacturer. It is preferred to confirm converter has ASE/CSA qualified technicians installing conversion kits. 3
    • Converted CNG Vehicle Purchase (Continued) Guidance: Do some research. 3. Expand knowledge base. Use the following documents to educate yourself in the basics. • “Have Your Vehicle Converted to Compressed Natural GasSafety”, Clean Vehicle Education Foundation (http://www.cleanvehicle.org/committee/technical/PDFs/Con vert_Your_Vehicle_Safely_Final.pdf). • “Fact Sheet: Converting Light Duty Vehicles to Natural Gas”, NGVAmerica (http://www.ngvc.org/pdfs/FAQs_Converting_to_NGVs.pdf.) 4. Determine fueling logistics. Want to identify and secure at lease two fueling options. 4
    • CNG Vehicle Inspection Guidance: Know the facts. 1. ANSI NGV 2 (fuel tank spec) requires an inspection of the fuel tank every 3 years. 2. TP-304-03 FMVSS (CNG Fuel Container Integrity), National Highway Traffic Safety Administration requires additional “or 36,000 miles” for tank inspection. 3. NFPA 52 requires that a tank is inspected ─ After an accident or fire ─ Before it is reinstalled in a vehicle 5
    • CNG Vehicle Inspection (Continued) Guidance: Know the facts. 4. The Compressed Gas Association (CGA) defines a qualified inspector as: • 2 years experience conducting inspections • Supervision by person with 2 years experience conducting inspections • Approved by fuel cylinder manufacturer • Certification from original equipment manufacturer through training center • Certification from nationally recognized organization e.g. CSA • Certification as inspector by Authority Having Jurisdiction 6
    • CNG Vehicle Inspection (Continued) Finding an certified inspector: • CSA provides certification for CNG fuel system inspection which includes all major components and tanks. • CSA offers a list of qualified and certified fuel system inspectors on their website. http://www.csagroup.org/us/en/services/educationand-training/personnel-certification/people-search CNG Fuel System Inspection Training • CVEF List (http://www.cleanvehicle.org/technology/cylinder.shtml) 7
    • Municipal/Licensing Entity CNG Vehicle Inspection • GTI has prepared a template checklist for inspection of CNG vehicles • Checklist is available and will be accessible on CACC, WICC, and SSCC websites • Checklist is NOT a substitute for certified vehicle inspections 8
    • LPG Vehicle Purchase Guidance: Do some research. 1. US EPA and CARB certified conversion kits and engine platforms are allowable under current federal regulation. • EPA Website: Certified Clean Alternative Fuel Conversion Systems http://www.epa.gov/otaq/consumer/fuels/altfuels/documen ts/certified-conversions.xls • PERC List: http://www.autogasusa.org/uploadedFiles/Fuel/Fueling_Wi th_Propane/OTR_Manufacturer_Listing_Public_View_Up dated_Jan_2014.pdf 9
    • LPG Vehicle Purchase (Continued) Guidance: Do some research. 2. Confirm converter has trained technicians installing conversion kits. (NFPA 58) • • Propane autogas technician course and training (PERC partnership with National Alternative Fuels Training Consortium) OEM approved/trained installations 3. Expand knowledge base. Use the following website to educate yourself in the basics. Propane Education and Research Council (PERC) website is useful. • www.autogasusa.org 10
    • LPG Vehicle Purchase (Continued) Guidance: Do some research. 4. Determine fueling logistics. You may want to secure at lease two fueling options. 11
    • LPG Vehicle Inspection Guidance: Know the facts. 1. Propane containers are certified by ASME or DOT • DOT cylinders are mainly used for industrial and off road applications such as forklifts, mowers, etc. 2. NFPA 58 states fuel containers have to be requalified per Compressed Gas Association inspection criteria. Good practice to include vehicles involved in fire and/or auto accidents. 3. Follow OEM specifications for inspections/training. 4. NFPA 58 requires vehicle fuel system to be leak free prior to garage storage or service. 12
    • Municipal/Licensing Entity LPG Vehicle Inspection • GTI is preparing a template checklist for inspection of LPG vehicles • Checklist will be accessible on CACC, WICC, and SSCC websites • Checklist is NOT a substitute for experienced vehicle inspections 13
    • WI State Vehicle Inspection 1. The Wisconsin Department of Transportation‟s (WDOT) State Patrol conducts safety inspections on the following vehicle types, ambulances, motor buses, school buses, human service vehicles, farm vehicles, salvage titled vehicles, and homemade/reconstructed vehicles. 2. WDOT participates in Motor Carrier Safety Assistance Program (MCSAP), which federally mandates a safety audit which includes vehicle inspection for vehicles transporting goods and passengers in interstate commerce. 14
    • Acknowledgement of Support 15
    • Questions? Thank you for your time. 16
    • Phillip Mailey Business Manager North Central Region 734.891.4349 phillip.mailey@roush.com PROPANE AUTOGAS: A CLEAR CHOICE Powered by:
    • ABOUT US Company Background & History
    • Roush Fenway Racing
    • Enterprise Brand Portfolio Roush Fenway Racing Dominant NASCAR Sprint Cup racing team. ROUSH Performance Industry leading high performance vehicles. ROUSH Life Sciences Medical equipment design, manufacturing and engineering. ROUSH Industries OEM manufacturing, engineering, prototyping and design.
    • Wheel of Capability
    • Alt. Fuel Experience Propane Autogas – Over 4,000 vehicles sold. – Service, warranty, sales infrastructure in place. Compressed Natural Gas (CNG) • Design of fuel system. • Calibration. Electric – Over 16,000 recharging stations built. – Blink ECOtality contract with U.S. DOE. Hydrogen • 207.297 MPH (world land-speed record.)
    • ROUSH CleanTech • Founded in 2010. • Dedicated to developing quality alternative fuel solutions. • Propane autogas focus. • EPA and CARB certification ability. • Platform customization to suit customer needs. • Reduces operating costs, carbon footprint. • OEM support through Ford and BPN dealers. • Creating opportunities for partner companies. • Using American fuel and American technology.
    • Single Source Engineering and Support
    • Building 87 - RCT Headquarters •Manufacturing •Complex Assembly •Sales & Marketing •Engineering •Warranty & Field Service
    • State of the Art Facility
    • Building 79 – Vehicle Assembly
    • ORDER PROCESS: Minimizing Time from Order to Delivery
    • Liquid Propane Autogas Ford E-150/250/350/450 Ford E-450 Ford F-250/350 Ford F-450/550 Ford F-650 Ford F-59 Strip Chassis Ford E-450 Strip Chassis Micro Bird G5 Blue Bird Vision
    • Propane Powered Vision
    • Blue Bird Bus Dealer
    • Product Overview Model Years 2015 Engine Size 6.8L V10 (3V) Applications All cab configurations. All wheelbase configurations. 6-speed automatic transmission. Fuel Tank Capacity Mid-Ship: 67 gallons (usable) Extended: 93 gallons (usable) Technical Specifications EPA and CARB approved. GVWR: 33,000 lbs. Up to 77 passengers Order Availability Blue Bird dealers Blue Bird Vision (Type C)
    • Product Overview Model Years 2015 Engine Size 6.8L V10 (2V) Applications All cab configurations. 158” / 176” wheelbase configurations. 5-speed automatic transmission. Fuel Tank Capacity Aft-Axle: 41 gallons (usable) Technical Specifications EPA and CARB approved. GVWR: 14,500 lbs. Up to 30 passengers Order Availability Blue Bird dealers Micro Bird G5 (Type A)
    • E-250/350/450 E-450 Cutaway F-250/350/450/550/650 F-53 / F-59 Strip Chassis E-450 Strip Chassis
    • Order to Delivery Process Order the Vehicle Order the Fuel System Ford Build Process • Check applicable body codes. • Check applicable wheelbase. • Order gaseous fuels prep engine package. • Enter ship-thru code. • Dealer places order through Ford • Determine tank configuration. • Dealer places order through ROUSH CleanTech. • Ford builds vehicle. • Ford delivers vehicle to ship-thru location. Ship-Thru Build Process Vehicle Delivery • Complete standard upfit. • Complete propane autogas upfit. • Vehicle re-enters Ford shipping. • Vehicle is delivered to destination for final customer delivery.
    • Product Overview Model Years 2009 - 2014 Engine Size 5.4L V8 (2V) Applications Extended or Regular Cargo Van, Club Wagon. All rear-axle configurations. 4-speed automatic transmission. Fuel Tank Capacity Mid-Ship: 25 gallons (usable) In-Cab: 46 gallons (usable) Technical Specifications EPA and CARB approved. GVWR: < 10,000 lbs. Requires “91G” gaseous fuels prep. package. Order Availability Ford Ship Through. Conversion Kits. Ford E-250 / E-350
    • Product Overview Model Years 2009 - 2014 Ford E-450 Cutaway Engine Size 6.8L V10 (2V) Applications 158” / 176” / 186” / 190” / 208” wheelbase. Stretched chassis. 5-speed automatic transmission. Fuel Tank Capacity Aft-axle: 41 gallons (usable) Technical Specifications EPA and CARB approved. GVWR: < 14,500 lbs. Requires “91G” gaseous fuels prep. package. Order Availability Ford Ship Through. Conversion Kits. s
    • Product Overview Model Years 2012 - 2014 Engine Size 6.2L V8 (3V) Applications 4x2 or 4x4. All bed configurations. All body configurations (including chassis cab). Fuel Tank Capacity Under-bed*: 21 gallons (usable) In-Bed: 38 gallons (usable) In-Bed Extended Range: 46 gallons (usable) Technical Specifications EPA and CARB approved. GVWR: < 13,300 lbs. Requires “98F” gaseous fuels prep. package. Order Availability Ford Ship Through. Conversion Kits. Ford F-250 / F-350
    • Product Overview Model Years 2012- 2014 Engine Size 6.8L V10 (3V) Applications All cab configurations. All wheelbase configurations. 5-speed automatic transmission. Fuel Tank Capacity Aft-Cab*: 52 gallons (usable) Shuttle: 65 gallons (usable) Technical Specifications EPA and CARB approved. GVWR: < 16,500 – 19,500 lbs. Requires “98G” gaseous fuels prep. package. Order Availability Shuttle: Q1, 2013 (distributed through GAS only). Ford F-450 / F-550
    • Product Overview Model Years 2012- 2014 Engine Size 6.8L V10 (3V) Applications All cab configurations. All wheelbase configurations. 6-speed automatic transmission. Fuel Tank Capacity Skirted: 45 gallons (usable) Non-Skirted: 83 gallons (usable) Technical Specifications EPA and CARB approved. GVWR: < 30,000 lbs. Requires “98G” gaseous fuels prep. package. Order Availability Available Now Ford F-650
    • Product Overview Model Years 2013 - 2014 Engine Size 6.8L V10 (3V) Applications All wheelbase configurations. All rear-axle configurations. 5-speed automatic transmission. Fuel Tank Capacity Aft-axle: 65 gallons (usable) Technical Specifications EPA and CARB approved. GVWR F-53: < 26,000 lbs. GVWR F-59: < 22,000 lbs. Requires “98G” gaseous fuels prep. package. Order Availability Available from Green Alternative Systems. Ford F-53 / F-59 Strip Chassis
    • Coming Soon Ford Transit
    • INSTALLATION PROCESS: Minimizing Time from Order to Delivery
    • Fuel Tank FRPCM Fuel Rail The liquid propane autogas fuel tank meets all ASME certification standards, is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA. The Fuel Rail Pressure Control Module ensures consistent vehicle performance and power on-demand. ROUSH CleanTech‟s signature blue anodized aluminum fuel rail is designed to operate under varying temperatures of liquid propane Fuel Fill Industry-standard valve designed to allow for safe passage of liquid propane into the vehicle. Includes a check valve to prevent fuel leaks. Fuel Lines Fuel Injectors Special fuel injectors are used to inject liquid propane into the cylinders for ignition. Made of high-durability stainless steel to handle varying temperatures and pressures. They are designed to route through the factory line locations.
    • Fuel System  67.5 or 93 gallon capacity tank.  Carbon steel.  Twice the required thickness for ASME Certification  312 PSI working pressure.
    • Fuel System 16 Mounting Points Located Inside Frame Rails
    • E-250/350/450 E-450 Cutaway F-250/350/450/550/650 F-53 / F-59 Strip Chassis E-450 Strip Chassis
    • Installation Partners Located Throughout the U.S. Trained by ROUSH CleanTech FORD QVM Certified Installation maintains factory Ford warranty
    • ROUSH CleanTech LPG System Overview  The ROUSH CleanTech LPG system is a dedicated liquid propane injected system and completely replaces the OEM fuel system.  The conversion process involves removing the OEM fuel tank assembly, the evaporative emissions assembly, the fuel line assembly and the fuel rail assembly.  The vehicle then has the ROUSH CleanTech LPG system installed on it. An overview of the system hardware is shown.
    • System Installation Overview Fuel Rail Assembly – Fuel Rails – Fuel Injectors – Injection Press. / Temp. Sensor Fuel Line Assembly – Fuel Lines – Flow Control Solenoid Fuel Tank Assembly – Fuel Tank – Fuel Pump – Fuel Level Sensor Powertrain Control System – PCM Calibration – Wiring Harness
    • Ford E-450 Fuel Tank The liquid propane autogas fuel tank meets all ASME certification standards, is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA. FRPCM The Fuel Rail Pressure Control Module ensures consistent vehicle performance and power on-demand. Fuel Rail ROUSH CleanTech‟s signature blue anodized aluminum fuel rail is designed to operate under varying temperatures of liquid propane Fuel Fill Industry-standard valve designed to allow for safe passage of liquid propane into the vehicle. Includes a check valve to prevent fuel leaks. Fuel Injectors Special fuel injectors are used to inject liquid propane into the cylinders for ignition. Fuel Lines Made of high-durability stainless steel to handle varying temperatures and pressures. They are designed to route through the factory line locations.
    • Ford E-150 / E-250 / E-350 FRPCM The Fuel Rail Pressure Control Module ensures consistent vehicle performance and power on-demand. Fuel Rail ROUSH CleanTech‟s signature blue anodized aluminum fuel rail is designed to operate under varying temperatures of liquid propane Fuel Fill Industry-standard valve designed to allow for safe passage of liquid propane into the vehicle. Includes a check valve to prevent fuel leaks. Fuel Tank The liquid propane autogas fuel tank meets all ASME certification standards, is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA. Fuel Injectors Fuel Lines Special fuel injectors are used to inject liquid propane into the cylinders for ignition. Made of high-durability stainless steel to handle varying temperatures and pressures. They are designed to route through the factory line locations.
    • Ford E-150 / E-250 / E-350 FRPCM The Fuel Rail Pressure Control Module ensures consistent vehicle performance and power on-demand. Fuel Rail ROUSH CleanTech‟s signature blue anodized aluminum fuel rail is designed to operate under varying temperatures of liquid propane Fuel Tank The liquid propane autogas fuel tank meets all ASME certification standards, is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA. Fuel Injectors Fuel Lines Special fuel injectors are used to inject liquid propane into the cylinders for ignition. Made of high-durability stainless steel to handle varying temperatures and pressures. They are designed to route through the factory line locations. Fuel Fill Industry-standard valve designed to allow for safe passage of liquid propane into the vehicle. Includes a check valve to prevent fuel leaks.
    • ROUSH CleanTech LPG System Overview
    • Underfloor Tank
    • Ford F-250 / F-350 FRPCM The Fuel Rail Pressure Control Module ensures consistent vehicle performance and power on-demand. Fuel Rail ROUSH CleanTech‟s signature blue anodized aluminum fuel rail is designed to operate under varying temperatures of liquid propane Fuel Fill Industry-standard valve designed to allow for safe passage of liquid propane into the vehicle. Includes a check valve to prevent fuel leaks. Fuel Tank Fuel Lines Fuel Injectors Special fuel injectors are used to inject liquid propane into the cylinders for ignition. The liquid propane autogas fuel tank meets all ASME certification standards, is 20 times more puncture resistant than gasoline tanks, and is built and assembled in the USA. Made of high-durability stainless steel to handle varying temperatures and pressures. They are designed to route through the factory line locations.
    • Ford F-250 / F-350 FRPCM The Fuel Rail Pressure Control Module ensures consistent vehicle performance and power on-demand. Fuel Rail ROUSH CleanTech‟s signature blue anodized aluminum fuel rail is designed to operate under varying temperatures of liquid propane Fuel Fill Industry-standard valve designed to allow for safe passage of liquid propane into the vehicle. Includes a check valve to prevent fuel leaks. Fuel Tank Fuel Injectors Special fuel injectors are used to inject liquid propane into the cylinders for ignition. The liquid propane autogas fuel tank meets all ASME certification standards, is 20 times more puncture resistant Fuel Lines than gasoline tanks, and is Made of high-durability stainless built and assembled in the USA. steel to handle varying temperatures and pressures. They are designed to route through the factory line locations.
    • F-450 / F-550 Aft-Cab Aft-Cab Tank: 52 usable gallon capacity
    • F-650 Saddle Tanks Non-Skirted Body Tanks: 83 total usable gallon capacity Skirted Body Tanks: 45 total usable gallon capacity
    • Propane Autogas Tank Safety Features  The tank mounting plates are structurally mounted to the floor or frame using a total of (10) M12 bolts, with backing plates in all locations that do not already have a Ford structural anchor.  The tank is then isolation-mounted to these plates, providing structural and noise isolation between the tank and the floor so that any body flex does not result in stresses on the tank.  This system is designed to ROUSH CleanTech‟s internal mounting standards (tank will not become dislodged in 20g front crash, 8g side / rear) which is double the NFPA standard.  This ensures that the tank itself does not become dislodged in an accident.
    • Together We Practice Environmental Responsibility Together We Are Innovative Together We Succeed Phillip Mailey Business Development Manager – North Central Region 734.679.7526 phillip.mailey@roush.com
    • Turbocharged Natural Gas™ Dual Fuel System • Accelerating Natural Gas Adoption in Legacy HD Fleets • South Shore Clean Cities Webinar • January 28th, 2014
    • Publicly Traded Company (OTCQB – APGI) 22 employees/Forecasted revenue in fiscal 2014: $14M Facilities Operations & Worldwide Distribution Center Algona, IA Calibration & Emissions Tech Center Detroit, MI University of West Virginia Diesel Test Cell Morgantown, WV Leader in the Dual Fuel Natural Gas Conversions #1 in EPA engine approvals and units sold 2
    • New EPA Clean Alternative Fuel Engine Conversion Categories Engine Mileage (mi) 1305000 Outside Useful Life Approval 870000 435000 0 Full OEM Cert 0 Inside Useful Life Approval 2 4 6 8 10 12 Engine M o del Year Past Current 14 16 3
    • APG Engine Family Status for EPA Approvals 2001 – 1991 IUL – SCR (MY 2010 – 2012) DD15, DD13 2009 – 2008 Volvo/Mack (Jan „14) 2009 2009 – 1999 2006 – 1987 MBE 4000 12.8L 2009 – 2001 OM457LA, OM460LA 2003 – 2000 D11, D12, D13, D16 2009 – 2004 VE D12 2002 – 1996 MP7, MP8, MP10 2006 – 2002 E7 2006 – 1996 EM7 Mack 2009 – 1998 Series 60 12.7L, 11.1 Volvo ISX, ISM, ISL, ISC Series 60 14.0L Daimler 2003 – 1996 DD13 12.8L Detroit Diesel 2002 – 1997 N14, M11, L10, C8.3 Cummins 2006 – 2004 C-10, C-12, C-15 Caterpillar C11, C13, C15 C-16 OUL: 2002 – 1996 Detroit Diesel (Mar „14) Cummins (May „14) Note: Some engines may not have been produced in each year shown above and some horsepower ratings may not be included. Contact APG or an authorized distributor for more details 4
    • Turbocharged Natural Gas™ Technology V5000 Dual Fuel Upgrade System 6 6
    • V5000 Engine Kit Installed Throttle body to control NG substitution % Remote Display Unit ECM wire harness 3% by volume of Natural Gas in the turbo chamber. Low pressure regulator LEL(Lower Explosion Limit requires 5-15% by volume) 6 7
    • V' ea of VS 00 http://www.youtube.com/watch ?v=5309M UWuF1w
    • CNG Tank Installation 60” CNG tank = 30 DGE 90” CNG tank = 46 DGE 8
    • LNG Tank Installation 50” LNG tank = 37 DGE 90” LNG tank = 78 DGE 9
    • LNG / CNG Tank Capacity Comparison 90” 90” CNG tank = 46.5 DGE 90” LNG tank = 78 DGE 10
    • Tank Safety WheelTime and APG only utilize tank manufacturers that comply to NFPA52 tank safety standards. • Drop Test • Gunfire • Bonfire • Cycle Test • Burst • Boss torque • Impact/Chemical exposure • Flaw tolerance 72
    • Why purchase an APG V5000 system? T oday 100% Diesel $4ppg B A APG System 50/50 Blend $3ppg B Dedicated 100% Nat Gas $2ppg B A A Lower your overall fuel cost 73
    • CNG Customer Economics – Dual Fuel Class 8 Tractor/Trailer Estimated Miles Driven/Y ear 120,000 miles Diesel Only Estimated MPG 5.5 Annual Diesel Consumption 21,800 gallons Annual Cost @ $4.00/gallon $87,000/year Estimated Annual Fuel Savings $87,272.73 $90,000.00 $80,000.00 $65,454.55 Dual Fuel @ 50% Annual Diesel Consumption 10,900 gallons Annual Cost @ $4.00/gallon $44,000/year Equivalent CNG Consumption 10,900 gallons Annual Cost @ $2.00/DGE $22,000/year T otal Annual Dual Fuel Costs Dollars per Year $70,000.00 $60,000.00 $50,000.00 $40,000.00 $66,000/year EstimatedAnnual Savings $21,000 (25%) Return on Investment(ROI) $30,000.00 $20,000.00 $10,000.00 $0.00 Annual Fuel Cost (100% diesel) Annual Fuel Cost (Dual Fuel) Insert CNG or LNG price per gallon 17 months ($32k system) *Depends on mileage range and tank capacity The price differential between NG and diesel is the savings 13
    • Introducing the APG Dual Fuel Glider™ Best Natural Gas Trucks on the Road! • Lowest Purchase Price for a New Natural Gas Truck • Net Dual Fuel Savings: $0.12 - $0.20 / mile • Additional Maintenance & DEF Savings • Attractive Financing Plans Available 75
    • Glider Video http://www.ccjdigital.com/video-log-fueling-driving-natural-gas-glider-kit 76
    • Distribution Network (Installation/Service) 181+ Locations 3,500 Technicians 2,800 Service bays 1,500 Service Vehicles , . 77
    • Where do I fill the tank? http://www.afdc.energy.gov/locator/stations/ Natural Gas Stations in Service Today 78
    • Key Factors to Natural Gas Success The Dual Fuel Industry is a Game-Changer Diesel LNG DEF Abundant Natural Gas # of Fill Stations LNG CNG Competitive Tank Storage Viable Dual Fuel Users - Compressed Natural Gas (CNG) - Economic - Liquefied Natural Gas (LNG) - Environmental 79
    • APG EPA Approvals and Target Fleets Approval Type Outside Useful Life (OUL) Existing Used Trucks @ 10 years old or 435,000 mi Approval Status T argeted Fleet Attributes Smaller Fleets Owner / Operator Longer Trade Cycles (>7 yrs) Buys Used Trucks Re-man their own engines Glider Kits Small Fleets Use a re-man OUL engine Large Fleets Install in new tractor Owner / Operator Intermediate Useful Life (IUL) Existing Used Trucks @ 2 years old Small Fleets Large Fleets Owner / Operator 80
    • Key Takeaways of APG system 1. Fast ROI - SAVES YOUR FLEET MONEY!   12-24 month payback  System can be transferred to other trucks  2. Saves $.10 to $.20 per mile Convert 6 trucks with APG system for the same price as 1 new dedicated NG truck Your engine is still a diesel engine   No loss in power, torque nor fuel economy  No range anxiety - runs on 100% diesel if natural gas tank runs out  3. Natural Gas introduced into air intake (pre-turbo)…non-invasive No change to existing maintenance schedule EPA approved…over $8M invested to obtain approvals   4. 448 OUL approvals IUL approvals coming in 2014 Best and most reliable dealer service & install network 81
    • Thank you for attending! Dana Brewster Business Development Manager, Eastern Region Based in Cleveland, Ohio 2503 E Poplar St Algona, Iowa, 50511 Mobile: (440)488-9234 Phone: (515)395-1360 Ext. 155 dbrewster@americanpowergroupinc.com www.americanpowergroupinc.com 82
    • Barnes Green Energy was created to provide alternatives to conventional fuels which are not only cost effective but provide a “Green Solution” to vehicle fleet owners and managers
    • • The US Dept of Energy now forecasts a growing supply of natural gas that extends into the next century. New technologies that have evolved allow natural gas production to ramp up to a level not foreseen a decade ago. • To take advantage of this natural gas fuel abundance, and the resulting price advantage at the pump, Barnes Green Energy (BGE) was organized in April 2013 to develop infrastructure and provide fuel system conversions for compressed natural gas as a vehicle fuel. • BGE not only provides EPA Certified Natural Gas (CNG) fuel system conversions but offers a CNG fueling facility at our Nesbitt Road location in Madison in partnership with U.S. Oil/Gain Clean Fuel, which will come on line in the Spring of 2014.
    • Fuel System Conversions •BGE along with its business partner Barnes Power Equipment (BPE), have converted thirty vehicles to CNG fueling since starting in the fall of 2012. Of these, twenty conversions are for the Barnes Inc. fleet. The remaining ten are for other fleet owners such as United Beverage, Great Lakes Conservation Corp., UW Provision, Center Point Energies, and others. •BPE employs Certified Technicians for CNG conversions for GM, Chrysler (NatGasCar ) and Ford ( Altech Eco ) using conversion systems provided by the major CNG fueling system providers noted above.
    • Fuel System Conversions Timeline for conversions Typical conversions will take 2 – 3 days for completion once the pieces / parts have arrived at our shop in Madison. Conversion Costs Costs for conversions vary depending on vehicle make, year, engine size, original fuel type ( gasoline or diesel ), and number and size of tanks installed. The number and size of tanks are a major cost component in conversions, and are driven by desired range for the vehicle, among other considerations.
    • Fuel System Conversions There are three types of aftermarket conversions currently available. The most common conversion is “U.S. EPA Certified”, and covers the current model year as well as the previous two model year’s vehicles. The second type of conversion is commonly called “Intermediate - Approval by U.S. EPA”, and the third type is “Outside Useful Life - Approval by U.S. EPA” The link below will take you to a complete listing of vehicles and engines for which conversions are available: http://www.ngvamerica.org/pdfs/Available_Vehicles_and_Engines.pdf
    • Fuel System Conversions CNG Cylinders ( tanks ) Presently there are four types of tanks available, designated by a number. Type 1 tanks are all metal, steel or aluminum; Type 2 are a metal liner hoop wrapped with a composite material, usually fiberglass or carbon fiber. Type 3 tanks also use a metal liner but the liner is completely covered by the composite material. Type 4 tanks are composed of a gas tight plastic inner cylinder fully enclosed by a composite covering. Pricing for these tanks escalates rapidly as you move from Type 1 to Type 4 tanks.
    • CNG Tank Installation Example
    • Useful Links: Barnes Green Energy http://barnesgreenenergy.com/ Wisconsin Clean Cities http://www.wicleancities.org/ Natural Gas Vehicle Institute http://www.ngvi.com/ Alternative Fuels Data Center – Natural Gas Vehicles http://www.afdc.energy.gov/vehicles/natural_gas.html Alternative Fuels Data Center - Tools http://www.afdc.energy.gov/tools Alternative Fuels Data Center - Calculator http://www.afdc.energy.gov/calc/ Alternative Fuels Station Locator – U.S. and Wisconsin http://www.afdc.energy.gov/locator/stations/
    • CONTACT INFORMATION NAME: Jim Montgomery Email: jim@barnesgreenenergy.com www.barnesgreenenergy.com Phone: 608-395-8149 Cell, or 608-845-3230 Office