hl-6200 lng orca - chart...

HL-6200 LNG OrcaOperation Manual

Part Number 20568954, Rev. B 05/22/2013

Designed and Built by:Distribution and Storage Division 407 Seventh Street Northwest New Prague, MN 56071 Phone: 800.400.4683 / Fax: 952.758.8293

iiiOperation Manual – HL-6200 LNG Orca

ContentsImportant Safety Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viImportant Maintenance Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viRevision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

System Overview 1General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Design Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Operator Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Training Note (NFPA® Requirement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Service and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Site Preparation – General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Shore Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Danger, Warning and Caution Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Manufacturer Liability Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Major System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Onboard Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Onboard Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Transport Off-load Control Panel Pendant . . . . . . . . . . . . . . . . . . . . . . . 6Fuel Dispensing Control Panel Pendant . . . . . . . . . . . . . . . . . . . . . . . . 6Transport Off-load Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Rear Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety 9Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9General LNG Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Wear Proper Clothing and Protective Gear . . . . . . . . . . . . . . . . . . . . . . .10Keep Away from Flame or Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Remove Excess Pressure and Liquid . . . . . . . . . . . . . . . . . . . . . . . . . .10

Confined Space Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Properties and Hazards of LNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Things to Consider When Working in Confined Spaces . . . . . . . . . . . . . . . .11General Confined Space Safety Rules and Procedures: . . . . . . . . . . . . . . . .12

General First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Asphyxiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Ingestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Container Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Safe Traffic Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Orca Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Purpose and Scope of Alarms and Detection Equipment . . . . . . . . . . . . . . .17Gas and Heat Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Grounding Clamp and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Grounding Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Anti-tow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19SD-2 Outer Vessel Pressure Safety Element . . . . . . . . . . . . . . . . . . . . . .19

iv Contents Operation Manual – HL-6200 LNG Orca

Orca Controls 21Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Transport Off-load Control Panel Pendant . . . . . . . . . . . . . . . . . . . . . . . . .22Fuel Dispensing Control Panel Pendant . . . . . . . . . . . . . . . . . . . . . . . . . .22LI-1 Inner Vessel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Inner Vessel Pressure Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Pump Discharge Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Transport Off-load Pump Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . .25Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Gauge and Transmitter Units of Measurement . . . . . . . . . . . . . . . . . . . . . .28Air-operated Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Manual Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Generator Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Vacuum Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Vacuum Pumpout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Vacuum Thermocouple and Thermocouple Isolation Valve . . . . . . . . . . . . . .35

Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Transport Off-load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Dispense Connections and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Vent/Recirculation Connections and Hoses . . . . . . . . . . . . . . . . . . . . . . .38

Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Operation 41Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Using the Natural Gas Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Using 480V Shore Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Purging into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Initial Fill/Filling a Warm Orca . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Filling the Orca Using the Off-load Pump . . . . . . . . . . . . . . . . . . . . . . .45Manual Recirculation/Saturation . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Dispensing to Vehicle Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Dispensing in the Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Vehicle Venting – Vehicle Tanks that Require Higher Saturated Liquid . . . . . . .55Filling the Orca Using Transport Pressure . . . . . . . . . . . . . . . . . . . . . . .56

Valve Positions for Transit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Maintenance and Repair 65Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Generator (Genset) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Regular Inspection of the Trailer Suspension Components . . . . . . . . . . . . . .67Regular Inspection of all Running Gear and Automotive Components . . . . . . . .67Verification of Correct Emergency Stop Switch and Emergency Air

Shutoff Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Replacing a Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Pressure Vessel Safety Relief Valves (SV-1A, SV-1B and SV-1C) . . . . . . . . . . .69Thermal Safety Valves (TSV-5, TSV-6 and TSV-7) . . . . . . . . . . . . . . . . . .70

Replacing an Inner Vessel Pressure Indicator (PI-1A and PI-1B) . . . . . . . . . . . . .71Zeroing the Inner Vessel Level Indicator (LI-1) . . . . . . . . . . . . . . . . . . . . . .72Replacing the Inner Vessel Level Indicator (LI-1) . . . . . . . . . . . . . . . . . . . . .72Checking the Annular Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73Replacing the Vacuum Thermocouple, TC-1 . . . . . . . . . . . . . . . . . . . . . . . .73Replacing and Repairing Other Components . . . . . . . . . . . . . . . . . . . . . . . .74

vContentsOperation Manual – HL-6200 LNG Orca

Orca Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Repairs that Require Breaking the Annular Vacuum . . . . . . . . . . . . . . . . . . .74

Re-evacuating the Orca . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Replacing the O-ring on the Outer Vessel Pressure Safety Element, SD-2 . . . . . .76

Troubleshooting 79General Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Excessing Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79Primary and Secondary Pressure Vessel Safety Relief Valves . . . . . . . . . . . .79Saturation Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80Vacuum Thermocouple and Isolation Valve . . . . . . . . . . . . . . . . . . . . . .80LI-1 Inner Vessel Level Indicator and Associated Valves . . . . . . . . . . . . . . .81

Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Appendix A – MSDS A1

Appendix B – Process and Instrumentation Diagram B1

Appendix C – Liquid Level Chart C1

vi Contents Operation Manual – HL-6200 LNG Orca

Important Safety NoteConsult owner/operator’s company policies for working in a liquid or gaseous LNG environment . Unless the Orca and piping have been purged with nitrogen or other suitable gas, any gas (pressure) released from the Orca or any isolated piping, whether by normal action of a safety relief valve (vessel primary or secondary or line safety) or by the removal of a component for repair/replacement, will be LNG .

LNG being stored or transported in the Orca presents the same hazards of low temperature and product under pressure that the more common compressed, liquefied industrial gases (nitrogen and argon) present, but has the additional hazard of being flammable.

Any and all Operators, Maintenance Personnel or anyone else involved with using or working on these units must be fully aware of and fully trained to deal with these hazards . If you are not so aware and trained, DO NOT use or work on this equipment .

Follow the owner/operator’s company policies for working in an actual or potential LNG environment .

Please refer to the specific cautions listed in the Safety section of this manual, and study the Material Safety Data Sheet for Liquefied Natural Gas (Appendix A) before handling the product or operating the Orca . The MSDS has been supplied by the Encana Corporation .

Important Maintenance NotePlease make sure to read this entire manual before working on the Orca, particularly the Maintenance and Repair sections regarding Replacing the O-ring on the Outer Vessel Pressure Safety Element, SD-2, Re-evacuating the Orca and Replacing the Vacuum Thermocouple, TC-1 .

Also note that it’s important to perform the recommended Scheduled Maintenance, Generator (Genset) Maintenance and Periodic Maintenance listed in the Maintenance and Repair section in order to obtain the maximum service life from the Orca .

Revision LogRevision Level Date Description

A 07/30/2012 Initial publicationB 05/22/2013 Updated to current revision

1Operation Manual – HL-6200 LNG Orca

System Overview

General DescriptionThe Chart HL-6200 LNG Orca is designed to provide semi-mobile Liquefied Natural Gas (LNG) fueling capabilities . The completely self-contained Orca delivery unit can provide a temporary fueling facility to support interim operations . The Orca can provide both “warm” liquid for spark-ignited gas engine vehicle tanks, and “cold” liquid for high-pressure direct-injection vehicle tanks .

The major HL-6200 LNG Orca subsystems include the Generator, Main Control Panel, Air Compressor, Inner/Outer Vessels, Trailer, VAP-1 Saturation Heat Exchanger, Transport Off-load Pump, Rear Enclosure and emergency shutdown safety circuit .

System Features• Submerged dispensing pump capable of 30-50 GMP at 210 psig; 30 HP motor

• Transport Off-load Pump capable of 170 GPM (643.5 LPM) flow rate; 15 HP motor

• Temperature-compensated fuel metering system accurate to ±2 .5%

• Integrated pressure-build coil provides saturation rate of 70 psi per ½ hr .

• Integral gas and heat detection monitors and emergency stop controls with audible alarm

• On-board control air system

• Shore power with on-board standby generator capability

• LNG storage vessel with multi-layer super insulation and high-performance vacuum

• Stainless steel plumbing

• Stainless steel inner vessel with transverse baffle

• Felling FT-50-NN-TT Trailer with side deck plates and top decks .

• Control system designed for automatic fuel dispensing operation

Trailer

Inner/Outer Vessels

Rear Enclosure

GeneratorAir

Compressor

Main Control Panel

Transport Off-load Pump

VAP-1 Saturation Heat

Exchanger

2 System Overview Operation Manual – HL-6200 LNG Orca

SpecificationsNet LNG Capacity (at 90% trycock) 5,660 gal. [21,425 l]Net LNG Capacity (DOT trycock) 5,120 gal. [19,381 l]Maximum Allowable Working Pressure (MAWP) 160 psig [11,03 bar]Trailer Length (overall) 46 ft. 5 in. [14,1 m]Trailer Width (overall) 8 ft. 6 in. [2,59 m]Height with Vessel on Trailer (overall) 11 ft. 9 in. [3,58 m]Weight (tare) 33,500 lbs. [15,193 kg]Weight (90% Trycock) 53,310 lbs. [19,381 kg]Design Codes ASME Section VIII Division 1 (inner vessel)

USDOT MC-338

NFPA 52Electrical Design Codes UL

NEMA 12 (NEMA 7 as required)

Design ModificationsDO NOT use this system in any manner inconsistent with the instructions outlined in this manual .

DO NOT alter the system design, or perform any service inconsistent with the instructions outlined in this manual without the prior written approval of Chart Inc .

ALWAYS use replacement parts authorized by Chart Inc . when replacing parts on the fueling system .

Operator QualificationsChart HL-6200 Orcas are designed for safe and simple operation . Operators are expected to be knowledgeable regarding the nature of the cryogenic liquids/gasses with which they are working, as well as all applicable safety requirements . If Operators are not knowledgeable in handling and transferring cryogenic materials, it’s imperative that they obtain the necessary training before operating this equipment .

This manual contains several sections dealing with operating instructions, handling instructions and maintenance procedures . To fully understand these procedures, we recommend that Operators and Maintenance Personnel first become familiar with the Orca controls and indicators.

Training Note (NFPA® Requirement)The following is taken from the NFPA® 52: Vehicular Gaseous Fuel Systems Code, 2010 Edition.

“Training shall be conducted upon employment and every 2 years thereafter .”

Service and TrainingThe Chart HL-6200 LNG Orca fueling system has been designed for years of safe and dependable operation . In the event service or training is required, contact Chart at 1-800-838-0856 .

3System OverviewOperation Manual – HL-6200 LNG Orca

Site Preparation – General GuidelinesNote: The owner/operator is responsible for the preparation of the Orca installation site, including

compliance with all applicable local, state and federal codes and ordinances.

Factors that need to be considered when preparing the site for the HL-6200 LNG Orca include, but are not limited to, the following requirements:

• Containment – must be in compliance with local, state and federal codes and ordinances .

• Orca Landing Surface – level and flat to ±1 degree (both planes – front-to-back and side-to-side), but with water drainage away from the site area .

• Ground Hardness – hard enough to maintain level orientation of the Orca, not soft ground that allows the unit to sink or tip out of level .

• Lighting – area must be lighted for nighttime operation/dispensing .

• Barriers – must be erected to protect the Orca unit from inadvertent collision from other equipment .

• Shore Power (recommended) – provide 480V, three-phase, 60-amp shore power to the Main Control Panel .

Shore PowerAlthough the Orca can be powered by the onboard generator when necessary, Chart recommends that you operate the system using 480 VAC shore power when available . Remove the Cap and connect the 480 VAC shore power to the Shore Power Connection on the side of the Main Control Panel .

About this ManualThis manual is intended to provide the cryogenic service employee with information necessary to operate and maintain the Chart Model HL-6200 LNG Orca . It should be read and understood thoroughly by anyone who operates this equipment .

Danger, Warning and Caution SymbolsThis manual uses the symbols below to signal potentially dangerous conditions . Read this information carefully and take the necessary steps to protect personnel and property .

Danger! Is used to warn of immediate hazards that will cause severe personal injury or death.

Warning! Is used to call attention to a situation that could cause severe personal injury.

Caution! Is used to call attention to a situation that could cause minor personal injury or damage to the equipment or other property.

Shore Power Connection

Cap


Manufacturer Liability StatementThe manufacturer believes the information presented in this manual to be accurate and up to date and assumes no liability concerning use of information contained herein by any party . The information contained herein is not a recommendation to violate federal, provincial, state, or municipal laws or regulations .

Major System ComponentsNote: Refer to the Orca Controls and Operation sections in this manual for detailed descriptions of,

and operating procedures for the various system components.

Onboard Generator

The onboard generator is mounted on the front of the trailer and provides power to the system when shore power is not available . The generator is powered by a General Motors 3 .0L, four-cycle, four-cylinder engine that runs on LNG provided by the Orca .

Note: If power is provided by the onboard generator (genset), the genset must be operated and maintained per the manufacturer’s recommended duty cycle and maintenance schedule.

Two separate gas regulators regulate the LNG from the Orca tank to the generator:

• The PCV-1 Generator Regulator (pressure control valve) controls the LNG from the tank to the V-45 Generator Valve . The V-45 Generator Valve controls the LNG flow to the VAP-2 Warming Coil (vaporizer), which provides LNG vapor to the downstream PCV-2 Generator Regulator .

V-45 Generator

Valve

PCV-1 Generator Regulator

VAP-2 Warming

Coil


• The PCV-2 Generator Regulator regulates the final LNG vapor pressure to the generator engine .

Onboard Air Compressor

The onboard air compressor is mounted to the platform in front of the tank and provides compressed air to the system to operate the air-actuated valve, and for the compressed air hose used to clean the LNG fill nozzle. The compressed air system is automated and maintains pressure above 80 psi to operate the systems .

Main Control Panel

The Main Control Panel is mounted on the road side of the trailer . The Main Control Panel houses the main electrical components including the Flowcom flow processor, Allen-Bradley® Micro830™ Programmable Controller, main power disconnect, Allen-Bradley® PowerFlex® 70 AC Drive (variable-frequency drive), and the various relays, fuses and wiring connections .


Allen-Bradley® Micro830™

Programmable Controller

Flowcom

Allen-Bradley® PowerFlex® 70

Drive (VFD)


The controls on the Main Control Panel include:

• The ALARM SILENCE, and ALARM RESET push buttons,

• The GENERATOR/OFF/SHORE main power, FUEL DISPENSING, BATTERY CIRCUIT and EMERGENCY STOP switches,

• The various indicator lights that display the system status .

Refer to the Orca Controls/Main Control Panel subsection for a detailed explanation of the switch, push button and indicator light functions .

Transport Off-load Control Panel Pendant

The Transport Off-load Control Panel Pendant is mounted on the road side of the trailer by the off-load pump and contains the off-load pump controls and status indicator lights .

Fuel Dispensing Control Panel Pendant

The Fuel Dispensing Control Panel Pendant is mounted in the rear of the enclosure and contains the dispensing pump controls and function selector key switches .


Saturation Heat Exchanger VAP-1

The VAP-1 Saturation Heat Exchanger is mounted on the road side of the trailer .


The Transport Off-load Pump and Pump Motor located on the road side of the trailer below the main deck .

Note that there is an arrow on the Pump Motor Housing to indicate the correct direction of rotation .


Pump Motor

Pump Motor Housing


Rear Enclosure

The Rear Enclosure houses the dispensing pump, dispensing connections, and the system valves, gauges, transmitters and hoses . The Vent Stacks protrude through the top curb side of the Rear Enclosure .

Note that the Rear Enclosure has Retaining Latches on both sides that lock into the Rear Enclosure Doors to hold the Rear Enclosure Doors open .

Vent StacksRear Enclosure

Rear Enclosure

Door

Retaining Latch

Rear Enclosure


Safety

Safety SummaryThe manufacturer believes the information presented in this section to be accurate and up to date . The manufacturer assumes no liability concerning use of information contained herein by any party . The information contained herein is not a recommendation to violate federal, provincial, state, or municipal laws or regulations .

Although safety features have been installed to ensure safe operation and maintenance of the Orca, it is essential that all personnel having contact with this equipment become thoroughly familiar with all safety precautions and procedures contained in this manual. Personnel operating LNG (Liquefied Natural Gas) equipment should review all laws, rules and regulations pertaining to the use of LNG . Personnel must also be knowledgeable of the properties of LNG and the safety equipment required for handling LNG .

Refer to the MSDS (Material Safety Data Sheet) for additional information regarding the properties of LNG, safety equipment required for handling LNG, and safety, first aid and emergency procedures that must be followed when working around LNG . A copy of the MSDS is included in Appendix A – MSDS .

Note: Before using Methane (LNG) equipment, one should become familiar with National Fire Protection Agency Association (NFPA) 52: “Vehicular Gaseous Fuel Systems Code”, and with all local safety codes. The NFPA standard applies to the design, installation, operation and maintenance of liquefied natural gas (LNG) fueling (dispensing) facilities.

General LNG SafetyNatural Gas, Refrigerated Liquid

(with high methane content)DOT ID Number UN 1972Hazard Class Division 2.1Label Flammable Gas

The major Orca components contain pressurized LNG at cryogenic temperatures . The major Orca components generally consist of an inner pressure-containing component (such as a vessel or pipe) encased within an outer steel vacuum shell . The pressure container operates under medium to low pressure at extremely low temperatures . The Orca employs several safety systems to protect equipment and personnel from danger . However, personnel operating the Orca must always adhere to the safety precautions included in the section .

Warning! NEVER use components (valves, gauges, fittings, etc.) or piping as steps or footholds. Always use the appropriate equipment to access components for maintenance or repair.

10 Safety Operation Manual – HL-6200 LNG Orca

Wear Proper Clothing and Protective Gear

Accidental contact of LNG with skin or eyes may cause a freezing injury similar to a burn . Personnel must wear proper clothing and protective gear while working around the Orca, especially when making or breaking connections . Do not allow liquid to splash, spill or leak . Protect eyes and cover skin wherever the possibility of contact with liquid, cold equipment or cold gas exists . Use clean, easily-removable insulated gloves and long sleeves for arm protection . Cuff-less trousers should be worn over the shoes to allow spilled liquid to be shed away from the Operator’s body .

If cryogenic liquid or cold boil-off gas contacts an Operator’s skin or eyes, the affected tissue should be flooded or soaked with tepid water (105-115ºF or 41-46ºC). DO NOT USE HOT WATER. A physician should promptly examine all cryogenic burns that result in blistering or deeper tissue freezing .

Wear the following items whenever working around the Orca:

• Safety Glasses

• Clean Insulated Gloves

• Face Shield

• Apron

• Long Sleeved Shirt

• Cuff-less Trousers

• Appropriate Shoes

• Harnesses and Retrieval Lines (if entering confined spaces)

Keep Away from Flame or Spark

Natural gas is flammable. All general-purpose electrical equipment is prohibited in areas where LNG is stored or handled. LNG must be stored and transferred under positive pressure to prevent the infiltration of air or other gases. Keep LNG equipment away from open flames or electrical sparks. Never permit smoking in areas where LNG equipment is repaired, used or stored .

Caution! Due to the flammable properties and the risk of asphyxiation, LNG must never be stored in confined areas or areas unsuitable for LNG storage. Always exercise caution when storing LNG containers or parking LNG vehicles.

Remove Excess Pressure and Liquid

The LNG Orca is a pressurized system . LNG will boil and build up pressure in the inner vessel . Isolate the affected section and empty the section of liquid before removing parts or loosening fittings. Always remove parts and fittings in a safe manner. Working on a pressurized section in an unsafe or careless manner can cause serious injuries, or even death. External valves and fittings can become extremely cold and can cause painful burns to personnel who are not properly protected . Always empty LNG and remove pressure from the Orca before removing any parts or components .

The Orca piping system is equipped with relief valves to protect both personnel and the Orca from hazards due to excessive LNG pressure . DO NOT trap LNG between two shutoff valves without a relief device to protect piping . Trapped LNG can vaporize and rapidly increase pressure, causing pipes to burst .

11SafetyOperation Manual – HL-6200 LNG Orca

Confined Space Safety

Definition

A confined space is any area that by design has limited openings for entry and exit, and/or limited adequate natural ventilation . The space may contain or produce a hazardous atmosphere uninhabitable to humans .

Properties and Hazards of LNG

Although LNG is non-toxic, it can asphyxiate those working in confined spaces where there has been a release . Natural gas cannot be detected by the human senses since it is colorless, odorless and tasteless . Without adequate ventilation, natural gas will displace oxygen, creating an oxygen-deficient atmosphere incapable of supporting human life . The normal oxygen content of air is approximately 21% . Depletion of oxygen content in air, either by combustion or by displacement, is a potential hazard . All personnel must exercise caution when working in confined spaces and areas where there is a risk of an LNG release. Refer to the table below for symptoms associated with percent (%) values of oxygen deficiency.

% (Percent) Oxygen Content

Symptoms

16-21 No signs or symptoms14-16 Increase in rate and depth of breathing12-14 Deep respiration, quickened pulse, loss of coordination10-12 Irregular breathing, poor judgment, blue lips8-10 Nausea, loss of consciousness, ashen face6-8 Loss of consciousness, death (if not promptly moved to safety)4-6 Coma, convulsions, respiration ceases, death

As oxygen content falls below 12%, individuals may become mentally incapable of diagnosing the situation . The onset of symptoms such as sleepiness, fatigue, weariness, loss of coordination, errors in judgment and confusion may be masked by a state of “euphoria,” leaving victims with a false sense of security . Unconsciousness can be immediate with no warning as the oxygen content falls below 10% . Either rapid or gradual depleting of oxygen can lead to the onset of the above symptoms .

Warning! The symptoms listed above may occur much more quickly to persons with coronary, pulmonary or circulatory problems. Persons with such problems must exercise extreme caution when working in confined spaces, or in areas where there is a potential for an oxygen-deficient atmosphere to occur.

Things to Consider When Working in Confined Spaces

Individuals working in or around confined spaces must work in pairs (two persons). When one worker enters a confined space (Entrant), the other worker outside the confined space (Attendant) must constantly monitor the Entrant until the Entrant exits the confined space and returns to safety. Obviously, the Attendant outside the confined space is equally susceptible to asphyxiation if he or she enters the area to assist an Entrant. Personnel entering an oxygen-deficient confined space to rescue another worker must be equipped with self-contained breathing apparatus (SCBA) before entering the confined space. Lifelines are acceptable only if the area is free of obstructions and personnel can assist one another without constraint . Refer to the list below for rules and responsibilities pertaining to working inside of a confined space.


• The Site Supervisor must:

– Conduct a pre-entry briefing.

– Ensure entry permits are completed and that they are removed after work has been completed .

– Ensure all personnel are evacuated if necessary .

– Ensure all equipment is returned to the proper locations .

– Oversee all confined space activities.

• The Attendant outside the confined space must:

– Know the hazards of the confined space of which he or she is attending.

– Maintain communications (visual, voice or signal line communications) with Entrant(s) inside the confined space.

– Control access to the confined space.

– Summon emergency services in the event of an emergency .

– Assist rescue efforts from outside the confined space.

– Order a space evacuation if conditions require such action .

– Maintain an accurate count of Entrants inside the confined space.

– Attendant must never enter the confined space.

• Entrants entering a confined space must:

– Know the hazards of the confined space into which they are entering.

– Handle equipment appropriately and in a safe manner .

– Exit the confined space if an alarm is activated, communication is lost, unknown exposures are encountered, or if ordered to do so .

• Rescuers entering a confined space must:

– Understand the hazards of the confined space into which they are entering.

– Be equipped with self-contained breathing apparatus (SCBA) or air line breathing equipment before entering the confined area.

– Be certified in emergency first aid and CPR.

– Understand the appropriate entry procedures .

– Know how to use rescue equipment .

General Confined Space Safety Rules and Procedures:

• Potential confined space hazards must be tested in the following order:

1 . Oxygen Content

2 . Combustibility/Flammability

3 . Toxic Atmospheres


• Entrants must be allowed to observe all monitoring .

• Use more than one worker if necessary to rescue Entrants from a confined space known or suspected to be oxygen deficient.

• The Orca doors must always remain open while maintenance is being performed inside the rear enclosure .

• Continually monitor the atmosphere of the confined space the entire time it is occupied.

• Hot work is prohibited if the flammability level in the area is 10% of lower explosion level (LEL) or greater .

General First Aid

Asphyxiation

LNG is an asphyxiator capable of displacing air and creating an oxygen-deficient atmosphere. If someone is exposed to an LNG induced oxygen-deficient atmosphere:

• Remove the person to an area where there is fresh air .

• Give artificial respiration if the person is not breathing.

• Administer oxygen to any person having difficulty breathing.

• Seek immediate medical attention .

Skin

LNG contact with skin may cause freeze burns and frostbite. If skin is exposed to LNG:

• Remove all contaminated clothing .

• Flush the contaminated area with cool or lukewarm water . Do not use hot water .

• Seek immediate medical attention if blistering, freezing or frostbite occurs .

Eyes

LNG contact with eyes may cause freeze burns, frostbite and permanent eye damage . If there is an LNG incurred eye injury:

• Soak eyes with cool or lukewarm water . Do not use hot water .

• Open eyelids to allow LNG to evaporate .

• Protect eyes with a clean cloth or handkerchief if eyes are sensitive to light .

• Do not apply ointment or any other medication to the eyes unless directed to do so by authorized medical personnel .



Ingestion

Although ingestion is highly unlikely, LNG can cause freeze burns or frostbite to exposed mucous membranes. If LNG is ingested:

• Do not induce vomiting . This could allow LNG to be inhaled into the lungs, creating additional injuries .

• Rinse the mouth with water .

• Administer one or two glasses of water or milk . Never administer liquids to an unconscious person .


Container SafetyCryogenic containers are at times exposed to unforeseen catastrophic environmental and ecological conditions . Extra caution must always be taken whenever a cryogenic container is involved in an incident compromising the container or its safety devices . Always exercise extreme caution whenever a container has been involved in a highway accident, immersed in water, exposed to extreme heat or fire, or exposed to adverse weather and ecological conditions (earthquakes, tornadoes, hurricanes, etc .) .

Always exercise extra caution if a container is suspected of abnormal operation . In the case of known or suspected container vacuum problems (even if extraordinary circumstances such as those noted above have not occurred), do not continue to use the unit . Continued use of a cryogenic container that has a vacuum problem can lead to more severe conditions, including the container becoming brittle and cracking . The outer steel jacket may rupture due to inordinate stress conditions caused by an internal liquid leak .

Carefully empty contents from a damaged or suspect container as soon as possible . Never, under any circumstances, leave product in a damaged container for an extended period. Do not refill a damaged container until it is repaired and re-certified. It is strongly recommended that damaged containers be returned to Chart for repair, evaluation and re-certification before they are re-used.

Safe Traffic FlowVehicle fill receptacles must point toward the rear of the Orca. Park vehicles to allow for a clear, unobstructed view of both the vehicle being fueled and for easy access to the Orca controls .

Caution! Always leave an appropriate amount of space between the vehicle and the Orca to allow for a safe and timely egress in the event of an emergency.

Note: Portions of the preceding information were extracted from Safety Bulletin SB-2 from the Compressed Gas Association, Inc. Additional information regarding oxygen and cryogenics is available from the CGA. Write to: (CGA) Compressed Gas Association, Inc., 1235 Jefferson Davis Highway, Arlington, VA 22202.


Orca Safety Features

Emergency Stop Switches

The HL-6200 Orca is equipped with four Emergency Stop switches that will stop the off-load or dispensing operations when pressed . The Emergency Stop switch locations are shown below .

• To reset the Emergency Stop switches on the Main Control Panel, Transport Off-load Control Panel Pendant and Fuel Dispensing Control Panel Pendant, simply pull the switch buttons out .

• To reset the Emergency Stop switch on the road side of the trailer by the generator, rotate the switch button clockwise, then pull the switch button out .

Emergency Stop Switch on Road Side of Trailer by Generator

Emergency Stop Switch on Main Control Panel

Emergency Stop Switch on the Fuel Dispensing Control Panel Pendant

Emergency Stop Switch on the Transport Off-load Control Panel Pendant


An Emergency Air Shutoff Switch is mounted in the rear enclosure . Setting the Emergency Air Shutoff Switch to the Closed position will switch off the compressed air to the AOV-1 Air-operated Dispense Valve to shut off the LNG flow from the dispensing pump to the Dispense Connection, DC-1 .

Safety Valves

• The HL-6200 LNG Orca is equipped with three Pressure Vessel Safety Relief Valves that will vent to atmosphere if the pressure in the tank reaches the valve pressure setpoints .

• There are two Thermal Safety Valves that will relieve pressure if liquid becomes trapped between the valves at the off-load connections .

Emergency Air Shutoff Switch

Pressure Vessel Safety Relief Valves (3)

Thermal Safety Valves (2)


• The Thermal Safety Valve will relieve pressure if liquid becomes trapped between valve V-22 and the recirculation connection DC-5B .

Refer to the Orca Controls/Safety Valves subsection for locations and descriptions of the Safety Valves .

Purpose and Scope of Alarms and Detection Equipment

Although the HL-6200 LNG Orca is equipped with gas and heat detectors, this equipment is installed primarily to monitor equipment located inside the rear pump/valve enclosure and by the onboard generator . These monitors are not meant to serve as methane or flame detection for the rest of the site. Each site must be reviewed, and provisions must be made to implement all other necessary methane and flame detection needed at the particular site. Site-specific methane detection (portable monitoring units, upwind and downwind methane detectors, manual detection, etc .) may meet site requirements as set by agencies (federal, state, county, city, etc .) having jurisdiction over such matters . Consult the appropriate authorities having jurisdiction for additional information concerning necessary alarms and detection equipment .

Gas and Heat Detectors

• There are two Gas Detectors on the Orca – one inside the rear enclosure and one mounted on the vertical plate behind the air compressor .

• The Heat Detector is mounted next to the Gas Detector inside the rear enclosure .

Thermal Safety Valve

Gas Detector

(behind air compressor)

Heat Detector

Gas Detector (inside rear enclosure)


Fire Extinguishers

There are two Fire Extinguishers, one on either side of the rear enclosure . The Fire Extinguishers are Amerex® model #423 with a U/L rating 20A:120B:C.

It’s recommended that you check the contents and condition of both Fire Extinguishers every three to six months .

Grounding Clamp and Cable

The Grounding Clamp and Cable are fastened to a support bar in the rear enclosure . The Grounding Clamp is attached to the truck or vessel that is receiving the LNG from the Orca during dispensing .

Grounding Reel

The Grounding Reel is fastened to a support bar by the off-load pump . The clamp on the Grounding Reel is attached to the tank suppling LNG to the Orca during off-loading .

Fire Extinguisher (2)

Grounding Clamp

Cable

Grounding Reel


Anti-tow Valve

The Anti-tow Valve is located at the top of the rear enclosure and closes when the enclosure doors are closed . The Anti-tow Valve is pneumatically connected to the trailer air brakes . The air brakes can only be released when the enclosure doors and Anti-tow Valve are closed . The enclosure doors can only be closed when all hoses are back in the enclosure . This safety feature protects the equipment from damage in the event of a drive-away accident due to the equipment not being properly stowed .

SD-2 Outer Vessel Pressure Safety Element

The SD-2 Outer Vessel Pressure Safety Element is located on the curb side front of the outer tank . SD-2 is held in place by the annular vacuum and sealed with an O-ring, and is designed to fall off if annular vacuum is lost .

Anti-tow Valve



Orca Controls

Main Control PanelThe Main Control Panel is located on the road side of the trailer between the generator and the tank .

The switches, push buttons and indicators on the Main Control Panel function as follows:

• ALARM SILENCE – momentary push button; shuts off the audible alarm when pressed .

• VFD OK – green indicator light; switches on to indicate that the variable-frequency drive (VFD) for the dispensing and off-load pumps is operating correctly .

• ALARM DETECTOR/ALARM RESET – lighted momentary push button; lights to indicate an alarm condition . Once the alarm condition is corrected, pressing the ALARM DETECTOR/ALARM RESET push button will switch off the light in the button and place the system back into the operating mode . Note that the ALARM DETECTOR/ALARM RESET push button must be pressed each time the unit is powered up .

• FUEL DISPENSING FMS/MANUAL – two-position key switch; selects the MANUAL or FMS (fuel management system) fuel dispensing mode .

• AREA SAFE – green indicator light; switches on to indicate that neither of the gas detectors has detected gas, and that the heat detector has not detected any fire or flame.

• GENERATOR READY – green indicator light; switches on to indicate that the on-board generator is ready to start .

• BATTERY CIRCUIT DISABLE/ENABLE – two-position key switch; disables and enables the battery circuit to the generator and safety circuit .

• EMERGENCY STOP – maintained palm switch; stops all off-loading or dispensing operations when pressed . To reset the EMERGENCY STOP switch, pull the red knob out .

• COMP. WARNING – amber indicator light; switches on to indicate that the LNG composition is not within the normal range .

• LOW LEVEL – amber indicator light; switches on to indicate that the level of LNG in the tank is low .

• GENERATOR/OFF/SHORE – three-position power switch with lock-out/tag-out; selects the Orca power source (GENERATOR or SHORE power), or shuts off the power to the system (OFF) .

22 Orca Controls Operation Manual – HL-6200 LNG Orca

Transport Off-load Control Panel PendantThe Transport Off-load Control Panel Pendant is mounted on the road side of the trailer by the off-load pump . The switches, push buttons and indicators on the Pendant function as follows:

• OFF-LOAD TEMP. OK – amber indicator light; switches on to indicate that the off-load pump has cooled to a safe operating temperature .

• OFF-LOAD ENABLED – green indicator light; switches on to indicate that the DISP. PUMP/OFFLOAD PUMP key switch on the Fuel Dispensing Control Panel Pendant has been set to the OFFLOAD PUMP position .


• STOP – momentary push button; stops the off-load pump .

• START – momentary push button; starts the off-load pump when the OFF-LOAD ENABLED and OFF-LOAD TEMP. OK indicator lights are on .

Fuel Dispensing Control Panel PendantThe Fuel Dispensing Control Panel Pendant is mounted on the back of the enclosure . The switches, push buttons and indicators on the Pendant function as follows:

• START – green lighted push button; functions as follows:

– Lights when the DISP. PUMP/OFFLOAD PUMP key switch is set to the DISP. PUMP position .

– Switches on the dispense pump when pressed .

– Flashes when the Flowcom is in the calibration mode .

• STOP – momentary push button; stops the dispense pump .


• DISPENSE PUMP/AUTO/MAN RECIRC./MAN DISP. – three-position key switch; selects the dispensing mode as follows:

– AUTO – normal dispense mode; the Flowcom and PLC control the dispense functions .

– MAN RECIRC. – starts the dispense pump . This mode is used to saturate the liquid when required .

– MAN DISP. – starts the dispense pump, allows you to manually open the AOV-1 Air-operated Dispense Valve that controls the LNG from the dispensing pump to the Dispense Connection, DC-1 .

Warning! The MAN DISP. key switch position is only to be used in an emergency.

• DISP. PUMP/OFFLOAD PUMP – two-position key switch; selects the pump to be run .

23Orca ControlsOperation Manual – HL-6200 LNG Orca

LI-1 Inner Vessel Level IndicatorThe LI-1 Inner Vessel Level Indicator is a differential pressure gauge that displays the LNG level in the tank in inches of water . The LI-1 Inner Vessel Level Indicator is mounted to the gauge panel inside of the rear enclosure . A liquid level conversion chart, attached to the inside of the rear enclosure door, allows you to convert inches of water to gallons or pounds of LNG, or to cubic feet of gas . (Refer to Appendix C – Liquid Level Chart .)

The LI-1 Inner Vessel Level Indicator is connected to the vapor and liquid lines at the top and bottom of the inner vessel respectively, and reacts to the pressure difference created by the weight of the liquid in the tank . The LI-1 Inner Vessel Level Indicator is largely unaffected by the total pressure in the tank .

The LI-1 Inner Vessel Level Indicator is connected with three valves; the V-11 LI-1 Vapor Phase (shutoff) Valve the V-12 LI-1 Liquid Phase (shutoff) Valve and the V-10 LI-1 Equalization Valve .

The V-10 LI-1 Equalization Valve connects to the liquid side and to the vapor side between the LI-1 Inner Vessel Level Indicator and the two shutoff valves . The V-10 LI-1 Equalization Valve is used for checking the LI-1 Inner Vessel Level Indicator . By closing both the V-11 LI-1 Vapor Phase Valve and the V-12 LI-1 Liquid Phase Valve and opening the V-10 LI-1 Equalization Valve, the pressure is equalized on both sides of the LI-1 Inner Vessel Level Indicator . If the LI-1 Inner Vessel Level Indicator is operating correctly it will read 0 inches of water column, regardless of the inner vessel pressure .

If the V-11 LI-1 Vapor Phase Valve, V-12 LI-1 Liquid Phase Valve and the V-10 LI-1 Equalization Valve are all left open at the same time, the instrument lines become a small buildup circuit and will cause a slow rise in inner vessel pressure . Note that at least one of these three valves should always be closed .

LI-1 Inner Vessel

Level Indicator

V-11 LI-1 Vapor Phase

Valve

V-12 LI-1 Liquid Phase

Valve

V-10 LI-1 Equalization

Valve


Inner Vessel Pressure IndicatorsThe Inner Vessel Pressure Indicators display the pressure inside of the inner vessel in pounds per square inch (psi) . Both Inner Vessel Pressure Indicators are 4½” dial, 0-160 psi, Bourdon-tube pressure gauges, and are connected to the gas phase line .

• The PI-1A Inner Vessel Pressure Indicator is mounted on the gauge panel inside of the rear enclosure .

• The V-11 LI-1 Vapor Phase Valve valve serves as the shutoff valve for the PI-1A Inner Vessel Pressure Indicator .

• The PI-1B Inner Vessel Pressure Indicator is located on the front head of the trailer in view of the driver’s rear view mirror .

• The V-14 PI-1B Shutoff Valve and the V-31 Vapor Phase Isol (isolation) Valve serve as shutoff valves for the PI-1B Inner Vessel Pressure Indicator .

PI-1A Inner Vessel

Pressure Indicator


Valve

PI-1B Inner Vessel

Pressure Indicator

V-14 PI-1B Shutoff Valve


Pump Discharge Pressure Indicator• The PI-2 Pump Discharge Pressure Indicator

displays the LNG pressure from the dispensing pump .

• The V-13 Pump Discharge Gauge Isol (isolation) Valve serves as a shutoff valve for the PI-2 Pump Discharge Pressure Indicator .

Transport Off-load Pump Pressure IndicatorThe PI-3 Off-load Pump Discharge Pressure Indicator displays the LNG pressure from the off-load pump .

PI-2 Pump Discharge

Pressure Indicator

V-13 Pump Discharge Gauge Isol Valve

PI-3 Off-load Pump Discharge

Pressure Indicator


Transmitters• The DP-1 Flow Meter Transmitter senses

the differential pressure from the flow dispense meter, M-1, and sends a signal to the Flowcom to enable the Flowcom to determine the mass flow.

• The PT-1 Pump Discharge Pressure Transmitter senses the pressure of the liquid from the dispensing pump outlet and sends this information to the VFD .

• The PT-2 Vessel Pressure Transmitter senses the inner vessel tank pressure and sends this information to the PLC .

• The LT-1 Vessel Level Transmitter is a differential pressure transmitter that senses the difference in pressure between the top of the inner vessel (Gas Phase line “G”) and the bottom of the inner vessel (Liquid Phase line “D”), and sends this information to the PLC .

DP-1 Flow Meter Transmitter

PT-1 Pump Discharge Pressure Transmitter

PT-2 Vessel Pressure Transmitter

LT-1 Vessel Level Transmitter


• The DT-1 Density Transmitter is mounted to the side of the P-1 Dispensing Pump . The DT-1 Density Transmitter senses the LNG capacitance in the P-1 Dispensing Pump and sends this information to the Flowcom . This enables the Flowcom to compute the LNG composition and determine the liquid quality .

• The TT-1 P-2 Pump temperature transmitter senses the off-load pump temperature and sends this information to the PLC .

P-1 Dispensing Pump

DT-1 Density Transmitter

TT-1 P-2 Pump


Gauge and Transmitter Units of MeasurementThe following tables list the system gauges and transmitters and their corresponding units of measurement .

Tag Gauge Description Units of Measurement

LI-1 Inner Vessel Level Indicator * Inches of Water (H2O)PI-1A Inner Vessel Pressure Indicator psiPI-1B Inner Vessel Pressure Indicator psiPI-2 Pump Discharge Pressure Indicator psiPI-3 Off-load Pump Discharge Pressure Indicator psi

Tag Transmitter Description Units of Measurement

DP-1 Flow Meter Transmitter mBarPT-1 Pump Discharge Pressure Transmitter psiPT-2 Vessel Pressure Transmitter psiLT-1 Vessel Level Transmitter * Inches of Water (H2O)

* Note that the Liquid Level Chart used to convert inches of water to gallons of liquid, weight of liquid in pounds and cubic feet of gas is included in Appendix C in this manual, and is also attached to the inside of the rear enclosure door .


Note: Also refer to Appendix B – Process and Instrumentation Diagram for valve and line locations.

Air-operated ValveThe AOV-1 Air-operated Dispense Valve controls the LNG from the dispensing pump to the Dispense Connection, DC-1 .

Manual Valves• The V-1 Off-load Inlet Valve controls the liquid

flow from Off-load Inlet Connection, DC-3, to the off-load pump inlet .

AOV-1 Air-operated

Dispense Valve

V-1 Off-load Inlet Valve


• The V-2 Off-load Return Valve controls the liquid flow from off-load pump discharge to the Off-load Return Connection, DC-4 .

• The V-5 Vapor Vent Valve controls the vapor flow from the tank Vent line (J) to the vent stack .

• The V-8 Vapor Sample Valve controls the vapor flow from the tank Vent line (J) to the Generator Regulator PCV-1 .

V-2 Off-load Return Valve

V-5 Vapor Vent Valve

V-8 Vapor Sample

Valve


• The V-16 Saturation Valve controls the liquid from the dispensing pump assembly to the Saturation Heat Exchanger, VAP-1 .

• The V-18 Full Trycock DOT Valve controls the liquid flow from the DOT Trycock line (C) and is used to confirm that the liquid level in the tank is at the maximum level allowed for transport .

• The V-19 Full Trycock 90% Valve controls the liquid flow from the 90% Trycock line (E) and is used to confirm that the liquid level in the tank is at 90 percent of maximum level .

V-16 Saturation Valve

V-18 Full Trycock

DOT Valve

V-19 Full Trycock

90% Valve


• The V-20 Off-load Inlet Drain Valve and V-21 Off-load Return Drain Valve are used to purge the off-load lines of atmospheric gasses, and to relieve the line pressure before the hoses are disconnected from the off-load connections .

– V-20 is connected to the Off-load Inlet Connection, DC-3 .

– V-21 is connected to the Off-Load Return Connection, DC-4 .

Both valves vent to the vent stack .

• The V-22 Vent Return Isol (isolation) Valve controls the liquid from the Vent Connection, DC-5A, and from the Recirculation Connection, DC-5B, to the tank Bottom Fill line (B) .

• The V-31 Vapor Phase Isol (isolation) Valve controls the vapor from the tank Gas Phase line (G) to the V-14 PI-1B Shutoff Valve and the PI-1B Inner Vessel Pressure Indicator .

• The V-32 Liquid Phase Isol (isolation) Valve controls the liquid from the tank Liquid Phase line (D) to the V-12 LI-1 Liquid Phase (shutoff) Valve .

V-21 Off-load Return

Drain Valve

V-20 Off-load Inlet Drain Valve

V-22 Vent Return Isol Valve

V-32 Liquid Phase

Isol ValveV-31 Vapor

Phase Isol Valve


• The V-33 Sump Drain Valve is used to drain liquid from the dispensing pump sump .

• The V-40 Sat. (saturation) Force Feed Valve is connected to the line between the dispensing pump assembly and the V-16 Saturation Valve . The V-40 Sat. Force Feed Valve aids in initiating the liquid flow to the saturation heat exchanger, VAP-1 .

• The V-44 Vent Water Drain Valve allows you to drain any accumulated water from the vent piping .

V-40 Sat. Force

Feed Valve

V-33 Sump Drain

Valve

V-44 Vent Water Drain Valve


• The V-45 Generator Valve controls the gas vapor from the PCV-1 Generator Regulator to the VAP-2 Warming Coil .

Generator RegulatorsThe HL-6200 Orca has two Generator Regulators (referred to as Pressure Control Valves PCV-1 and PCV-2 in the P&ID) to reduce the gas pressure from the vent stack to a level where it can be utilized by the engine that powers the generator .

• PCV-1 Generator Regulator is located on the rear curb side of the trailer .

• PCV-2 Generator Regulator is mounted on the vertical plate behind the air compressor .

Vacuum Valves

Vacuum Pumpout Valve

The VV-1 Vacuum Pumpout Valve is mounted on the front of the tank and is used to evacuate the annular space, or to break vacuum for maintenance or repairs .

V-45 Generator

Valve



VV-1 Vacuum

Pumpout Valve


Vacuum Thermocouple and Thermocouple Isolation Valve

The VV-2 TC (thermocouple) Isol (isolation) Valve and TC-1 Vacuum Thermocouple are located on the rear of the tank inside of the rear enclosure . The TC-1 Vacuum Thermocouple is a Hastings Model DV-6, and is used with an appropriate vacuum gauge to check the annular space vacuum . The VV-2 TC Isol Valve controls the TC-1 Vacuum Thermocouple exposure to the annular vacuum .

Safety Valves• The SV-1A, SV-1B and SV-1C Pressure Vessel

Safety Relief Valves are connected to the vent line and will open to vent gas into the atmosphere if the pressure in the tank reaches the valve pressure set points .

– SV-1A and SV-1B are the primary valves and will open when the tank pressure exceeds 160 psig .

– SV-1C is the secondary valve and will open when the tank pressure exceeds 240 psig .

VV-2 TC Isol ValveTC-1

Vacuum Thermocouple

SV-1C Pressure Vessel Relief Safety Valve

SV-1B Pressure Vessel Safety

Relief Valve

SV-1A Pressure Vessel Safety

Relief Valve


• The TSV-5 and TSV-6 Overload Thermal Safety Valves will relieve the pressure if liquid becomes trapped between the valves at the off-load connections .

• The TSV-7 Vent Thermal Safety Valve will relieve the pressure if liquid becomes trapped between valve V-22 and the recirculation connection, DC-5B .

Connections

Transport Off-load Connections

The DC-3 Off-load Inlet Connection and DC-4 Off-load Return Connection are mounted on the road side of the trailer by the off-load pump .

TSV-5 Overload Thermal

Safety ValveTSV-6

Overload Thermal

Safety Valve

TSV-7 Vent Thermal Safety Valve

DC-3 Off-load Inlet

Connection

DC-4 Off-load Return

Connection


Dispense Connections and Hoses

• The Tran-4 Dispense Transfer Hose is connected to the AOV-1 Air-operated Dispense Valve that controls the LNG flow from the dispense pump to the Dispense Connection DC-1 .

• Tran-4 Dispense Transfer Hose and Tran-1 Dispense Transfer Hose are connected at the Break-away Dispensing Connection BC-1 .

The Air Lines to and from the AOV-1 Air-operated Dispense Valve are designed to separate and shut off the compressed air to AOV-1 if the Break-away Dispensing Connection BC-1 is broken .

AOV-1 Air-operated

Dispense Valve

Tran-4 Dispense Transfer

Hose

Break-away Dispensing Connection BC-1

Tran-1 Dispense Transfer Hose

Air Lines

Tran-4 Dispense Transfer Hose


• The LNG Fill Nozzle/DC-1 Dispense Connection is connected to the Tran-1 Dispense Transfer Hose .

Vent/Recirculation Connections and Hoses

• The Tran-3 Dispense Transfer Hose is connected to the S-3 Vent Strainer to the tank Bottom Fill line (B) .

• The Tran-3 Dispense Transfer Hose and Tran-2 Dispense Transfer Hose are connected at the Break-away Dispensing Connection BC-2 .

• The Tran-2 Dispense Transfer Hose is connected to the DC-5A Vent Connection . The DC-5A Vent Connection is used to vent back to the Orca tank when dispensing saturated “warm” liquid only .

LNG Fill Nozzle/DC-1 Dispense

Connection

Tran-1 Dispense

Transfer Hose

Tran-3 Dispense

Transfer Hose

Tran-2 Dispense

Transfer Hose

Break-away Dispensing Connection BC-2

DC-5A Vent Connection

Tran-2 Dispense

Transfer Hose


• The DC-5B Recirculation Connection is mounted on the left side of the rear enclosure and is connected to the Bottom Fill line (B) . The LNG Fill Nozzle/DC-1 Dispense Connection is connected to the DC-5B Recirculation Connection when recirculating liquid through the system to cool the dispensing pump or system components .

Digital DisplayThe Digital Display is mounted in the rear enclosure . The top line of the Digital Display shows the flow rate. The bottom line shows the total amount of liquid dispensed . Note that the Digital Display can be configured to display in several different units of measurement .

DC-5B Recirculation Connection

Digital Display


Operation

Initial Startup

Daily Inspection

The following should be inspected on a daily basis:

• Check the electrical cables for loose or damaged cables .

• Check the pipes, valves, fittings and connections for damage, malfunction or leaks.

• Check the pressure and level indicators for correct function .

Using the Natural Gas Generator

1 . Set the disconnect on the main control panel to the GENERATOR position . The following conditions must be met before the generator will start up:

• Both gas detectors must be below 40% LEL .

• The EMERGENCY STOP switches must be pulled out .

• There must be sufficient gas supply to the generator.

2 . ● If the above conditions are not met, the alarm horn will sound . The alarm horn can be silenced, but until the above conditions are met, the ALARM DETECTOR light will remain on and will not allow the generator to start . Press the ALARM RESET button to reset the alarm status .

● If the alarm conditions are satisfied, the ALARM DETECTOR light will switch off . Set the BATTERY CIRCUIT DISABLE/ENABLE two-position key switch on the main control panel to ENABLE to start the generator .

Using 480V Shore Power

1 . Connect the 480 VAC shore power to the Shore Power Connection on the side of the main control panel . Shore Power

Connection

42 Operation Operation Manual – HL-6200 LNG Orca

2 . Set the disconnect on the main control panel to the SHORE position . The following conditions must be met before the unit is able to operate:

• Both gas detectors must be below 40% LEL .

• The EMERGENCY STOP switches must be pulled out .

3 . ● If the above conditions are not met, the alarm horn will sound . The alarm horn can be silenced, but until the above conditions are met, the ALARM DETECTOR light will remain on and not allow normal operation . Press the ALARM RESET button to reset the alarm status .

● If the alarm conditions are satisfied, the ALARM DETECTOR light will switch off and the unit can operate normally .

Note: For normal operation, the BATTERY CIRCUIT DISABLE/ENABLE key switch needs to be set to ENABLE and the FUEL DISPENSING FMS/MANUAL key switch needs to be set to MANUAL.

Purging

General Information

It is necessary to purge the Orca to ensure that the product delivered from it will be of the correct purity .

How you purge the Orca will depend on the supplies and equipment available, and must be done according to the procedures supplied by the owner/operator . We offer some general comments below for purging the Orca “into service” . A major point is that no liquid should be allowed in the Orca until the gaseous contents are of the desired purity . Once contaminated liquid is in the Orca, it will be a slow and costly operation to remove it completely .

It is good practice to blow out all lines – particularly the Gas Phase and Liquid Phase lines (G and D respectively on the P&ID) – at some point prior to the initial fill. This is to ensure that all moisture is removed from the lines prior to the introduction of cryogenic liquid to the unit . Cryogenic liquid will freeze any moisture present and can create an ice block, particularly in a small gauge line . Particular caution must be exercised due to the hazards presented by exposure to LNG . Follow the owner/operator’s procedures for blowing out the gauge lines, using nitrogen or other suitable gas, prior to filling the unit with LNG.

Purging into Service

Prior to filling the Orca with LNG, the composition of the gas in the inner tank should be known, and it should be nitrogen or methane with very low oxygen content . If oxygen is present, it is necessary to purge with nitrogen . The simplest way to purge a pressure vessel is to pressurize with nitrogen, wait a while for mixing to occur, vent to atmosphere, then repeat until you obtain a suitable oxygen concentration .

Pressurize the Orca through the Top Fill line (A on the P&ID) . The sparger (spray header) will deliver nitrogen over most of the inner tank length to expedite mixing . Pressurizing to a low pressure, 15 psig for example, requires more repetitions but uses less nitrogen than pressurizing to higher pressures .

Thirty minutes for mixing has worked well for Orcas . If possible, analyze the gas exiting from the various lines to determine how much mixing time is required and when purging is complete .

Venting should be through all lines as mixing throughout long pipes would take too long .

43OperationOperation Manual – HL-6200 LNG Orca

Initial Fill/Filling a Warm OrcaThe initial fill (first fill ever for a unit, or any fill after an inner vessel has been out of service and has been allowed to “warm up”), differs from subsequent fills in two ways:

• The first is that the inner vessel must be “cooled” in a controlled manner so as not to introduce undue thermal stresses and possibly damage the vessel .

• Secondly, an initial fill is a time where previously unseen packing, gasket and instrument connection leaks will show up. Such leaks are not a manufacturing flaw or poor fabrication, but a result of the shrinking that takes place when a component is cooled from ambient temperatures to cryogenic temperatures .

When filling an Orca with LNG, the owner/operator must vent all purge gas and all excess vapor/pressure to an acceptable flare stack or other location. This will differ considerably from the filling of cryogenic trailers for atmospheric gas service (liquid oxygen, nitrogen or argon) .

Because of this, we recommend you refer to your company’s procedures for filling these units with LNG. We can offer the following general comments as guidelines only:

• A “warm” unit must be filled slowly initially, and with cold gas only through the Top Fill line (A on the P&ID) until the inner vessel is uniformly cooled . After approximately three hours, cryogenic liquid may be introduced, again slowly, through the Top Fill line . When a few “inches” of liquid have accumulated you can increase the filling speed to full capacity.

• Note that the Orca is designed to be top-filled only.

• Generally, when filling the unit with a flammable cryogen, vent gas must be captured and handled according to local and/or federal rules . Refer to the owner/operator’s policies .

• Monitor the PI-1A Inner Vessel Pressure Indicator and the LI-1 Inner Vessel Level Indicator while filling.

If the LI-1 Inner Vessel Level Indicator oscillates violently, partially close the V-11 LI-1 Vapor Phase and V-12 LI-1 Liquid Phase (shutoff) Valves . If necessary, close the V-12 LI-1 Liquid Phase Valve and open the V-10 LI-1 Equalization Valve to shut off the instrument .

If the LI-1 Inner Vessel Level Indicator has been shut off, periodically check it to see if it can sensibly be left in operation to determine the liquid level .

• Watch the Orca pressure – it will tend to rise quite rapidly in a vessel that has just been filled for the first time (or refilled after complete warming) .

LI-1 Inner Vessel

Level Indicator


Valve


Valve


Valve

PI-1A Inner Vessel

Pressure Indicator


• Make sure that the V-11 LI-1 Vapor Phase Valve, V-12 LI-1 Liquid Phase Valve, V-31 Vapor Phase Isol (isolation) Valve and the V-32 Liquid Phase Isol (isolation) Valve are open .

• Make sure that the V-10 LI-1 Equalization Valve is closed .


Valve


Valve


Valve

V-32 Liquid Phase


Phase Isol Valve


General OperationBecause of the hazards presented by the inhalation or mishandling of LNG, the user must follow his/her company’s (owner/operator) policies governing the operation of these units . The following are some general comments offered as information .

Filling the Orca Using the Off-load Pump

1 . Make sure there is power available to the Orca (shore power or natural gas generator) .

2 . Turn off the transport vehicle .

3 . Chock the transport wheels .

4 . Ground the transport vehicle by attaching the clamp on the Orca Grounding Reel to the transport .

5 . Turn the DISP. PUMP/OFFLOAD PUMP key switch on the Fuel Dispensing Control Panel Pendant to the OFFLOAD PUMP (clockwise) position .

The green OFF-LOAD ENABLED light on the Transport Off-load Control Panel Pendant will light to indicate that the off-load pump is enabled .

Grounding Reel


6 . Connect the transport liquid fill hose to the DC-3 Off-load Inlet Connection .

7 . Connect the transport return hose to the DC-4 Off-load Return Connection .

Note: When connecting the transport liquid fill hose to the DC-3 Off-load Inlet Connection, make sure:

• The Hose has a straight run from the Tanker to the Orca with no “sags” in the hose that could create a liquid trap and prevent the off-load pump from catching prime . (Refer to the drawings below .)

• The Hose is at least three inches in diameter, and no longer than 13 feet .

DC-3 Off-load Inlet

Connection


Connection

Tanker

Tanker

Orca

OrcaLiquid Trap

Hose run straight from Transport to

Orca

Note: Return hoses not shown

Sag in hose from

Transport to Orca


8 . Open transport tanker valves .

9 . Open the V-20 Off-load Inlet Drain Valve and the V-21 Off-load Return Drain Valve to purge the hoses and clear the moisture from hoses using the transport tanker pressure .

10 . Close V-20 and V-21 after the purge is complete .

11 . Check the hoses for leaks .

12 . Increase the tanker pressure per the transport owner/operator’s procedure .

13 . Reduce the Orca pressure to 80-100 psi, or as required to initiate liquid transfer .

14 . Begin pump cool-down by opening the V-1 Off-load Inlet Valve and the V-2 Off-load Return Valve .

15 . When the amber OFF-LOAD TEMP. OK light on the Transport Off-load Control Panel Pendant turns on, press the green START button . Note that it can take up to 30 minutes for the OFF-LOAD TEMP. OK light to switch on .

16 . Throttle the V-2 Off-load Return Valve to establish primed flow through the pump.

17 . Close the V-2 Off-load Return Valve once prime is established .


Drain Valve





18 . Monitor the LI-1 Inner Vessel Level Indicator and the appropriate Trycock Valve to make sure you don’t overfill the Orca . Filling will terminate automatically when the Orca reaches 90% full, or manually when the red STOP button on the Transport Off-load Control Panel Pendant is pushed .

19 . Close the transport valves when filling is complete.

20 . Open the V-20 Off-load Inlet Drain Valve and the V-21 Off-load Return Drain Valve to drain the hoses to the vent stack .

21 . Close the V-20 Off-load Inlet Drain Valve and the V-21 Off-load Return Drain Valve when draining is complete .

22 . Disconnect the liquid fill hose from the DC-3 Off-load Inlet Connection .

23 . Disconnect the return hose from the DC-4 Off-load Return Connection .

24 . Stow the hoses .

25 . Disconnect the transport ground cable .

26 . Remove the wheel chocks and move the transport from off-load area .


Drain Valve


DC-3 Off-load Inlet

Connection


Connection


Manual Recirculation/Saturation

The recirculation mode is used to cool down the dispense circuit or increase the liquid saturation pressure if required. The purpose is to cool down the piping to reduce the amount of liquid lost due to flash-off, or to fill vehicle tanks that require higher saturated liquid to operate .

The manual recirculation mode will circulate liquid as long as the following conditions are met:

• There is a sufficient amount of liquid in the tank for the pump to “catch prime”.

• The green VFD OK light is on .

1 . Open the V-16 Saturation Valve .

2 . Set the FUEL DISPENSING key switch to the MANUAL (clockwise) position .

3 . Turn the DISP. PUMP/OFFLOAD PUMP key switch on the Fuel Dispensing Control Panel Pendant to the DISP. PUMP (counterclockwise) position .



4 . Set the DISPENSE PUMP key switch to the MAN RECIRC. (middle) position . The unit will start recirculating liquid as soon as key switch is set to the MAN RECIRC. position .

5 . Monitor the tank pressure to the desired saturation pressure .

6 . To terminate the manual recirculation/saturation mode, set the DISPENSE PUMP key switch to the AUTO (counterclockwise) position .

Warning! In the manual recirculation/saturation mode, the STOP button on the Fuel Dispensing Control Panel Pendant will not terminate operation. Only moving the key switch to the AUTO (counterclockwise) position or faulting a safety condition will terminate operation.


Dispensing to Vehicle Tanks

1 . To dispense in the automatic mode, make sure the following conditions are met:

• The generator is running or the 480V shore power is on .

• The ALARM DETECTOR light is not illuminated .

• The VFD OK light is on .

• The START button on the Fuel Dispensing Control Panel Pendant is illuminated .

• There is sufficient liquid in the tank for the dispensing pump to “catch prime”.

• There is sufficient compressed air pressure to open the AOV-1 Air-operated Dispense Valve (≈80 psi).

2 . Turn off the vehicle and attach the Grounding Clamp to the vehicle .

3 . For vehicle tanks using saturated liquid, vent the vehicle pressure to 120-150 psi as necessary to initiate dispensing .

4 . Verify that the coupling and receptacle sealing surfaces are free of frost and debris .

5 . Connect the LNG Fill Nozzle/DC-1 Dispense Connection to the vehicle tank . At this point the HPDI tanks can be vented to 120-150 as necessary to initiate dispensing .

Grounding Clamp


Connection




8 . Set the DISPENSE PUMP key switch to the AUTO (counterclockwise) position .

9 . Press the START button on the Fuel Dispensing Control Panel Pendant .

10 . Monitor the filling by observing the Digital Display in the rear cabinet .

Dispensing is terminated when either of the following occurs:

• The dispensing is stopped automatically due to low flow, or,

• The red STOP push button on the Fuel Dispensing Control Panel Pendant is pressed .

11 . When the dispensing is complete, disconnect and stow the fuel coupling .

12 . Remove the grounding clamp from the vehicle .

Digital Display


Dispensing in the Manual Mode

Caution! Dispensing in the manual mode is not to be used in normal operation.

The manual dispense mode is used if dispensing with the Flowcom is not required .

1 . To dispense in the manual mode, make sure the following conditions are met:

• There is a sufficient amount of liquid in the tank for the pump to “catch prime”.

• There is sufficient compressed air pressure to open the AOV-1 Air-operated Dispense Valve (≈80 psi).

2 . Turn off the vehicle and attach the Grounding Clamp to the vehicle .

3 . For vehicle tanks using saturated liquid, vent any excessive vehicle pressure to 120-150 psi as required .

4 . Verify that the coupling and receptacle sealing surfaces are free of frost and debris .

5 . Connect the LNG Fill Nozzle/DC-1 Dispense Connection to the vehicle tank . At this point the HPDI tanks can be vented to 120-150 as necessary to initiate dispensing .


Grounding Clamp


Connection



8 . The pump will start dispensing liquid as soon as DISPENSE PUMP key switch is set to the MAN DISP. (clockwise) position .

9 . Press and hold in the START and STOP push buttons on the Fuel Dispensing Control Panel Pendant for five seconds to open the AOV-1 Air-operated Dispense Valve .

10 . To terminate the manual dispense mode and close the AOV-1 Air-operated Dispense Valve, set the DISPENSE PUMP key switch to the AUTO (counterclockwise) position .

Warning! In the manual dispense mode, the STOP button on the Fuel Dispensing Control Panel Pendant will not terminate operation. Only setting the DISPENSE PUMP key switch to AUTO, or faulting a safety condition will terminate operation. The unit will immediately start to dispense once the key switch is set to MAN DISP. Ensure that all hoses are properly connected and fittings tightened prior to setting the key switch to the MAN DISP. position.

11 . Remove the grounding clamp from the vehicle .


Vehicle Venting – Vehicle Tanks that Require Higher Saturated Liquid

1 . Connect the DC-5A Vent Connection to the vehicle .

2 . Open the vehicle vent valve .

3 . Open the V-22 Vent Return Isol (isolation) Valve to vent to the Orca liquid (maintaining Orca pressure) .

4 . Close all valves .

5 . Remove the DC-5A Vent Connection from the vehicle .

DC-5A Vent Connection



Filling the Orca Using Transport Pressure

1 . Secure the transport .

2 . Attach the fill hose to the DC-4 Off-load Return Connection .

3 . Purge the fill hose through the V-21 Off-load Return Drain Valve .

4 . Open the V-2 Off-load Return Valve .


Connection


Drain Valve



5 . Vent the Orca through the V-5 Vapor Vent Valve as required to establish flow from the transport.

6 . Open the V-19 Full Trycock 90% Valve when the liquid level in the Orca approaches 25 inches of water column .

7 . Terminate filling when liquid is discharged from the V-19 Full Trycock 90% Valve .

8 . Close the V-5 Vapor Vent Valve .

9 . Drain the hose pressure through the V-21 Off-load Return Drain Valve .

10 . Stow the hoses .


V-19 Full Trycock

90% Valve


Valve Positions for TransitMake sure that the following valves are in the positions specified below prior to transit:

Tag Tag Definition/Valve DescriptionValve

Position for Transit

V-1 Off-load Inlet Valve ClosedV-2 Off-load Return Valve ClosedV-5 Vapor Vent Valve ClosedV-8 Vapor Sample Valve Closed

V-10 LI-1 Equalization Valve ClosedV-11 LI-1 Vapor Phase Valve OpenV-12 LI-1 Liquid Phase Valve OpenV-13 Pump Discharge Gauge Isol Valve OpenV-14 PI-IB Shutoff Valve OpenV-16 Saturation Valve ClosedV-18 Full Trycock DOT Valve ClosedV-19 Full Trycock 90% Valve ClosedV-20 Off-load Inlet Drain Valve ClosedV-21 Off-load Return Drain Valve ClosedV-22 Vent Return Isol Valve ClosedV-31 Vapor Phase Isol Valve OpenV-32 Liquid Phase Isol Valve OpenV-33 Sump Drain Valve ClosedV-40 Sat. Force Feed Valve ClosedV-44 Vent Water Drain Valve ClosedV-45 Generator Valve ClosedVV-1 Vacuum Pumpout Valve ClosedVV-2 TC Isol Valve Closed

Note: These valves and their transport positions are illustrated on the following pages.



V-5 Vapor Vent Valve – Closed

V-1 Off-load Inlet Valve – Closed


V-2 Off-load Return Valve – Closed


V-8 Vapor Sample Valve – Closed

V-8 Vapor Sample

Valve


V-11 Vapor Phase Valve – OpenV-10 LI-1 Equalization Valve – ClosedV-12 LI-1 Liquid Phase Valve – Open

V-13 Pump Discharge Gauge Isol Valve – Open


Valve


Valve


Valve

V-13 Pump Discharge Gauge Isol Valve

V-14 PI-1B Shutoff Valve – Open


V-16 Saturation Valve – Closed



V-18 Full Trycock

DOT Valve

V-19 Full Trycock

90% Valve

V-18 Full Trycock DOT Valve – ClosedV-19 Full Trycock 90% Valve – Closed


Drain Valve


V-20 Off-load Inlet Drain Valve – ClosedV-21 Off-load Return Drain Valve – Closed

V-22 Vent Return Isol Valve – Closed


V-32 Liquid Phase


Phase Isol Valve

V-31 Vapor Phase Isol Valve – OpenV-32 Liquid Phase Isol Valve – Open


V-44 Vent Water Drain Valve – Closed

V-44 Vent Water Drain Valve

V-45 Generator Valve – Closed

V-45 Generator

Valve

V-40 Sat. Force

Feed Valve

V-33 Sump Drain

Valve

V-33 Sump Drain Valve – ClosedV-40 Sat. Force Feed Valve – Closed


VV-1 Vacuum

Pumpout Valve

VV-1 Vacuum Pumpout Port Valve – Closed

VV-2 TC Isol Valve

VV-2 TC Isol Valve – Closed


Maintenance and Repair

Caution! Consult the owner/operator’s company policies for working in a liquid or gaseous LNG or methane environment. Unless the Orca and piping have been purged with nitrogen or other suitable gas, any gas (pressure) released from the Orca or any isolated piping, whether by normal action of a safety relief valve (vessel primary or secondary or line safety), or by the removal of a component for repair/replacement, will be LNG or natural gas.

LNG being stored or transported in the Orca presents the same hazards of low temperature and product under pressure that the more common compressed, liquefied industrial gases (nitrogen and argon) present, but has the additional hazard of being flammable.

Any and all Operators, Maintenance Personnel or anyone else involved with using or working on these units must be fully aware of and fully trained to deal with these hazards. If you are not so aware and trained, DO NOT use or work on this equipment.

Please refer to the information and specific cautions and warnings in the Safety section of this manual, and study the Material Safety Data Sheet (MSDS) listed in Appendix A before handling the product or preforming any maintenance or repairs on the Orca.

Scheduled Maintenance

Maintenance Function Daily Weekly Monthly Quarterly AnnuallyEvery Five

YearsDrain moisture from the vent stack. X X X X X XFill and vent hoses - check for leaks, damage and wear (loose braid conditions). Repair or replace as necessary.

X X X X X X

Valves, piping and tank – check for leaks and malfunctions. Repair as necessary or contact Chart Inc.

X X X X X

Inspect the compressor belts. Check the compressor oil level. Add oil and replace worn belts if necessary.

X X X X X

Check the grounding clamp. X X X X XFuel nozzle – check for LNG leaks, nozzle purge leaks and wear. Repair as necessary.

X X X X X

Ensure compliance with DOT ongoing test and inspection requirements per 49CFR 180.

X X

Ensure the Fire Extinguishers are charged and functional. X X X X

Check for moisture in the electrical control panels. X X X X

Check the air tube fittings on the control panel skid for leaks. Repair as necessary. X X X

66 Maintenance and Repair Operation Manual – HL-6200 LNG Orca

Maintenance Function Daily Weekly Monthly Quarterly AnnuallyEvery Five

YearsCalibrate the Methane Sensor (as needed). X X X

Visually inspect the Safety Relief Valves. X X XCheck the operation of the ESD system. X X XCheck the operation of the Heat Detector. X X XInspect the lift plate to ensure it has not been altered. Contact Chart Inc. for repair if necessary. Grease (Vacuum Grease) the lift plate between the lift plate and the flange during vacuum repairs (to be performed by Chart Inc.).

X X

Purge the air lines of all water. X XCheck the vacuum of the Tank Annular Space (to be performed by Chart Inc. in the event of suspected vacuum failure).

X X

Off-load Pump – Replace the mechanical shaft seal annually (or every 1000 hours). Replace the bearings every two years (or every 2000 hours).

X X

Submerged Centrifugal Pump - Inspect every 4000 hours. Overhaul every 8000 hours.

X

Generator (Genset) Maintenance

Maintenance Function50 Hours 43 Point

Inspection

100 Hours Basic Service

300 Hours Coolant

500 Hours Plugs & Wires

1000 Hours Detailed

GeneratorInspect Engine Lube X XInspect Coolant System X X XInspect Fuel System X XInspect Engine Ignition System X X XInspect Air Intake System X XInspect Starting System X XInspect Battery and Charger X XInspect Alternator X XInspect Exhaust System X XChange Engine Oil XChange Engine Oil Filter XChange Coolant Filter XChange Fuel Filter XDrain and Refill Coolant System XReplace Coolant Hoses XReplace Thermostat X

67Maintenance and RepairOperation Manual – HL-6200 LNG Orca

Maintenance Function50 Hours 43 Point

Inspection

100 Hours Basic Service

300 Hours Coolant

500 Hours Plugs & Wires

1000 Hours Detailed

GeneratorReplace Belts XReplace Spark Plugs XReplace Ignition Wires XInspect Slip Ring and Brushes XGrease Rear Generator Bearing XInspect Generator Wiring XInspect Stator and Rotor XInspect Generator Space Heater XInspect Couplings and Guards XInspect Meters and Voltage Regulator

X

Adjust Engine Intake and Exhaust Valves

X

Calibrate Injectors XCheck Engine Timing where Applicable

X

Periodic Maintenance

Regular Inspection of the Trailer Suspension Components

Follow the recommendations of the suspension component manufacturers . This includes visual inspections and verifying torque requirements .

Regular Inspection of all Running Gear and Automotive Components

This includes tires, wheels, axles, air brakes, lights and reflectors, etc., in accordance with the manufacturer’s recommendations and government and industry standards .


Verification of Correct Emergency Stop Switch and Emergency Air Shutoff Switch Operation

This requires regular verification that:

• All off-load and dispensing functions stop when any of the four Emergency Stop switches is pressed .

• The air-operated dispense valve, AOV-1, closes when the Emergency Air Shutoff Switch is set to the EMERGENCY SHUTOFF CLOSED position .

Emergency Stop Switch on Road Side of Trailer by Generator

Emergency Stop Switch on Main Control Panel

Emergency Stop Switch on the Fuel Dispensing Control Panel Pendant

Emergency Stop Switch on the Transport Off-load Control Panel Pendant

Emergency Air Shutoff Switch


Replacing a Safety Valve

Pressure Vessel Safety Relief Valves (SV-1A, SV-1B and SV-1C)

If any of the Pressure Vessel Safety Relief Valves should relieve for other than its intended purpose, fail to relieve when it should or is considered deficient for any reason, it must be repaired or replaced . You must blow the inner tank pressure down to zero psig prior to removing any Pressure Vessel Safety Relief Valve . The inner tank may or may not have to be purged to nitrogen depending on the owner/operator’s requirements . In all cases, Operators must exercise extreme caution, taking into consideration both the potential pressure hazards present and the flammability hazard also present with methane .

1 . Disconnect the malfunctioning Pressure Vessel Safety Relief Valve from the inlet and outlet connections and remove it from the piping .

2 . Install a new Pressure Vessel Safety Relief Valve .

3 . Once installed, build some pressure in the Orca and leak-test the inlet joint .



Relief Valve


Relief Valve


Thermal Safety Valves (TSV-5, TSV-6 and TSV-7)

1 . Isolate the malfunctioning Thermal Safety Valve by closing the appropriate manual valve(s) .

2 . Loosen the Thermal Safety Valve by using one wrench on the Thermal Safety Valve and another on its inlet and outlet fittings.

3 . Wait for the pressure to bleed down, then remove the Thermal Safety Valve .

4 . Install the new Thermal Safety Valve using thread sealant, and again use two wrenches to avoid twisting the inlet or outlet piping .

5 . Open the manual valves closed above and check for leaks . Exercise extreme caution, taking into consideration both the potential pressure hazards present and the flammability hazard also present with methane .

TSV-5 Overload Thermal

Safety ValveTSV-6

Overload Thermal

Safety Valve

TSV-7 Vent Thermal Safety Valve


Replacing an Inner Vessel Pressure Indicator (PI-1A and PI-1B)To remove either of the two Inner Vessel Pressure Indicators:

1 . Isolate the Inner Vessel Pressure Indicator from the Orca pressure as follows:

• If you’re replacing Inner Vessel Pressure Indicator PI-1A, open the V-10 LI-1 Equalization Valve and close the V-11 LI-1 Vapor Phase Valve .

• If you’re replacing Inner Vessel Pressure Indicator PI-1B, close the V-14 PI-1B Shutoff Valve .

2 . Carefully and slowly loosen the connection just enough to bleed off the line pressure .

3 . Remove the Inner Vessel Pressure Indicator .

4 . Apply thread sealant to new threaded joints, then install the new or repaired Inner Vessel Pressure Indicator .

5 . Leak-test the new joints .

6 . Return the Inner Vessel Pressure Indicator to the Orca pressure as follows:

• If you’ve replaced the Inner Vessel Pressure Indicator PI-1A, open the V-11 LI-1 Vapor Phase Valve and close the V-10 LI-1 Equalization Valve .

• If you’ve replaced the Inner Vessel Pressure Indicator PI-1B, open the V-14 PI-1B Shutoff Valve .

PI-1A Inner Vessel

Pressure Indicator


Valve


Valve

PI-1B Inner Vessel

Pressure Indicator



Zeroing the Inner Vessel Level Indicator (LI-1)To zero the LI-1 Inner Vessel Level Indicator:

1 . Open the V-10 LI-1 Equalization Valve .

2 . Close both the V-11 LI-1 Vapor Phase and V-12 LI-1 Liquid Phase Valves .

3 . Tap the LI-1 Inner Vessel Level Indicator lightly .

4 . If tapping the LI-1 Inner Vessel Level Indicator doesn’t zero the pointer, adjust the pointer as follows:

a . Remove the four bezel screws and remove the bezel and lens assembly .

b . Grasp the pointer hub between your thumb and forefinger.

c . Use a straight blade screwdriver to adjust the screw on the pointer clockwise to adjust the pointer upscale, or counterclockwise to adjust the pointer downscale .

d . Tap the LI-1 Inner Vessel Level Indicator lightly to confirm that the pointer is on zero.

e . Reinstall the bezel and lens assembly .

5 . Open the V-11 LI-1 Vapor Phase and V-12 LI-1 Liquid Phase Valves .

6 . Close the V-10 LI-1 Equalization Valve .

Replacing the Inner Vessel Level Indicator (LI-1)To replace the LI-1 Inner Vessel Level Indicator:

1 . Open the V-10 LI-1 Equalization Valve .

2 . Close both the V-11 LI-1 Vapor Phase and V-12 LI-1 Liquid Phase Valves .

3 . Loosen the tube nuts at the LI-1 Inner Vessel Level Indicator inlet .

4 . Wait for the pressure to bleed off, then disconnect the tubing .

5 . Remove the V-11 LI-1 Vapor Phase and V-12 LI-1 Liquid Phase Valve fittings from the malfunctioning LI-1 Inner Vessel Level Indicator .

6 . Loosen the mounting screws holding the LI-1 Inner Vessel Level Indicator to the gauge panel and remove it .

7 . Install the replacement LI-1 Inner Vessel Level Indicator into the gauge panel .

8 . Install the V-11 LI-1 Vapor Phase and V-12 LI-1 Liquid Phase Valve fittings onto the new LI-1 Inner Vessel Level Indicator using Teflon® tape or other suitable thread sealant .

9 . With the V-10 LI-1 Equalization Valve open, open the V-11 LI-1 Vapor Phase Valve and check the joints for leaks .

10 . When all the joints are tight, open the V-12 LI-1 Liquid Phase valve and close the V-10 LI-1 Equalization Valve .

LI-1 Inner Vessel

Level Indicator


Valve


Valve


Valve


Checking the Annular VacuumThe TC-1 Vacuum Thermocouple is the standard Chart Hastings Model DV-6 vacuum probe, and is used with an appropriate vacuum gauge to check the annular space vacuum . The VV-2 TC (thermocouple) Isol (isolation) Valve and TC-1 Vacuum Thermocouple are located on the rear of the tank inside of the rear enclosure . The VV-2 TC Isol Valve controls the TC-1 Vacuum Thermocouple exposure to the annular vacuum .

To check the annular vacuum:

1 . Select a compatible instrument to read the output from the TC-1 Vacuum Thermocouple vacuum probe .

2 . Plug the instrument into the probe and calibrate the instrument .

3 . Open the VV-2 TC Isol Valve . Note that VV-2 TC Isol Valve handle protrudes through protective housing and can be turned without removing the housing .

4 . Wait for five minutes, then take a vacuum reading.

5 . Close the VV-2 TC Isol Valve and take a second reading .

6 . Monitor the rate of rise in the vacuum probe with the VV-2 TC Isol Valve closed . If the vacuum continues to rise at a constant rate, it is possible that the probe assembly is leaking . Consult the factory .

7 . Verify that the VV-2 TC Isol Valve is closed .

8 . Compare the vacuum reading obtained now to the reading taken prior to shipping .

Replacing the Vacuum Thermocouple, TC-1

Caution! Unauthorized changing of the vacuum thermocouple will void the vessel warranty!

To replace the Vacuum Thermocouple:

1 . Close the VV-2 TC Isol Valve .

2 . Unscrew the old Vacuum Thermocouple, being very careful not to disturb the silver-soldered joints on each side of the valve . (It may be necessary to hold the valve with a wrench .)

3 . Thoroughly clean the threads on the bushing in the VV-2 TC Isol Valve and on the Vacuum Thermocouple tube .

4 . Put thread-sealant on the new or repaired Vacuum Thermocouple tube (starting one thread from the open end) and screw it into the bushing in the VV-2 TC Isol Valve . Again, be careful of the silver-soldered joints .

Note: RectorSeal® and Torr Seal® are acceptable vacuum sealants for this purpose, but Teflon® tape is not a suitable sealant on vacuum joints.

5 . Check for leakage .


Vacuum Thermocouple


Replacing and Repairing Other ComponentsRefer to the System Overview and Troubleshooting sections, and the manufacturers’ technical literature for additional comments and information regarding replacing or repairing other components on the Orca .

Orca StorageConduct weekly checks of the inner vessel pressure indicators to ensure the inner vessel is kept under positive pressure during storage . If the pressure indicators show a decay in pressure, or if the pressure is zero, contact Chart immediately to determine the course of action to take . Periodic vacuum measurement is not required during storage .

If the unit is to be stored for a considerable period, it’s recommended that you purge the inner vessel to a nitrogen atmosphere . Otherwise, the unit must remain connected to an owner/operator-supplied acceptable flare stack or other vent system. In any event, to maintain the Orca in good condition during storage:

• Protect it from vandals and “valve twiddlers” .

• Maintain a positive pressure (of nitrogen or methane) in the inner vessel .

• Keep openings sealed against rain, dirt and insects .

• Keep the unit in a secured area, especially if it is stored with residual LNG in it .

Repairs that Require Breaking the Annular VacuumNote: The following procedures for Re-evacuating the Orca and Replacing the O-ring on the Outer

Vessel Pressure Safety Element, SD-2, are presented as general notes and guidelines, and are meant to be used for reference only. Re-evacuating the Orca annular space requires specialized equipment and should only be attempted by experienced technicians that have been trained in these procedures.

If there are issues with the Orca annular vacuum or related components, it’s highly recommended that you contact your authorized service provider, or arrange to return the unit to Chart for repairs.

Re-evacuating the Orca

Heat leak into the Orca inner vessel increases with increasing pressure (deterioration of the vacuum) in the annular space . As heat leak increases, hold-time decreases . A high-quality annular space vacuum is required to maintain the thermal performance (or low normal evaporation rate – NER) that the insulation installed in the HL-6200 LNG Orca provides . Gettering (or absorbing) materials are installed in the annular space to maintain the required high-quality vacuum over a long period of time . None the less, a regular system of monitoring the condition of the annular space vacuum and of pumping it down, as needed, must be established .


Annular Vacuum Specifications

The insulation space vacuum should be less than five microns when the Orca is “cold” and less than 20 microns when the Orca is warm . Variations above these levels may be tolerable, but the drop in thermal performance will become noticeable when the cold vacuum level is above ten microns . Also, warm vacuum will increase with increasing ambient temperature and with exposure to direct sunlight . The 20-micron warm vacuum level cited above is an early morning (at or before sunrise) reading . For comparison purposes, it is important to take vacuum readings at the same time of day to make accurate comparisons from one day or week or month to the next .

Vacuum Pumps, Additional Equipment and Procedures

When pumping on the annular space, the owner/operator’s company policies must be followed due to the hazards presented by the flammability of methane.

Evacuation of the annular space is normally done with a mechanical vacuum pump . The pump must be equipped to prevent backflow of pump fluid into the annular space in case of a power failure. A solenoid valve or electropneumatic vacuum valve in the pumping line will do this, and will also stop loss of the annular vacuum . This valve must be controlled to close when power is lost and must be reopened only by an Operator, i .e ., not automatically . The line from the vacuum pump must then be re-evacuated and cleaned as necessary before opening it to the Orca again . Alternatively, a trap in the pumping line, large enough to hold the pump’s entire fluid charge, will prevent fluid backflow but will not prevent loss of annular vacuum.

For re-evacuating a cold Orca, a compound pump with a minimum capacity of eight to 10 cfm is suggested . For a warm Orca, where pressures are likely to be higher and gas volumes are likely to be larger, a two-stage pump of 20 to 30 cfm capacity is more suitable. In either case a suitable flexible hose is needed. This can be either flexible metal or reinforced rubber. (This reduces the amount of vibration transmitted from the pump to the Orca .)

It is highly recommended that a liquid nitrogen cold trap be included in the evacuation circuit between the tank vacuum valve and the vacuum pump. The liquid nitrogen cold trap has three primary advantages:

• First, it prevents back-streaming of pump oil to the tank annular space . This occurs at low vacuums on both roughing pumps and diffusion pumps as the flow of material from the tank annular space to the pump slows .

• Second, it will capture condensable materials that come out of the tank annular space, primarily water vapor, and keep them out of the pump oil. This prevents degradation of the pump capacity/efficiency, as condensable materials in the pump oil would limit the capacity of the pump by raising the vapor pressure of the pump oil .

• Third, the cold trap acts as an efficient pump for removing condensable materials, again primarily water vapor, from the tank annular space .

In lieu of a liquid nitrogen cold trap, the gas ballast on the pump may be used to drive the moisture out of the pump oil periodically . However, this will not prevent the back-streaming of pump oil to the tank annular space, nor will it offer the added pumping capacity of the cold trap .

For an Orca with no vacuum at all, it is recommended that the initial vacuum pumping (from 0 to 30 inches HG vacuum) be done slowly to prevent damage to the insulation materials in the Orca annular space. A gauge reading in inches of mercury (“ HG) vacuum attached to the vacuum space is required .


One way to do this is to connect the gauge to tee on the vacuum pump connection to the VV-1 Vacuum Pumpout Valve on the Orca . Then connect and start the pump to evacuate the line . It is desirable to have a thermocouple tube at the pump, and to check that the pump and line blank-off as low as they should before opening VV-1 . Slowly begin to throttle open VV-1 so the vacuum gauge (inches of HG vacuum) goes from 0 to 30” HG vacuum in two hours (minimum) uniformly, i .e ., at a rate of 4” HG vacuum (maximum) in 15 minutes . Once 30” HG vacuum is reached, VV-1 can be opened slowly to full open to evacuate the Orca to 20 microns or less .

For an Orca with a 1,000 micron or better (lower) vacuum, the inches of mercury vacuum gauge is not required . Connect the pump and hose to VV-1, start the pump and evacuate the line, then slowly open VV-1 . It is desirable to have a thermocouple tube at the pump, and to check that the pump and line blank-off as low as they should before opening VV-1 .

The thermocouple gauge can be used while pumping to get an idea of progress . However, sometimes there is an appreciable gradient within the insulation space while pumping . When the pumping is stopped, pressures equalize and pressure at the tube may increase . Therefore, when evacuation appears complete, close the evacuating valve, wait 10 minutes, and re-read the gauge . If there is no change, evacuation is complete .

Replacing the O-ring on the Outer Vessel Pressure Safety Element, SD-2

Use caution and follow your company’s guidelines in getting to the Outer Pressure Safety Element, SD-2 . If you use a ladder, make sure it is fastened securely .

While it is possible to replace the O-ring on the Outer Vessel Pressure Safety Element while there is LNG in the Orca, it is strongly recommended that you do not do this because the insulating value of the insulation is greatly reduced when the vacuum is broken . This will cause the Orca pressure to climb more rapidly than normal, and it will be more likely that you’ll have to vent excess methane vapor . A worse situation can occur when the cold inner vessel draws moisture into the annular space and freezes it. It will then be extremely difficult to obtain a high-quality vacuum with that moisture present in the annular space .

If you absolutely must replace the Outer Vessel Pressure Safety Element O-rings with liquid methane in the Orca, make sure that the Orca’s vent stack is correctly piped to a suitable flare/vent stack if required, then break the Orca vacuum with dry nitrogen according to the following procedure. Make sure that you have sufficient quantities of dry nitrogen available so you can maintain a constant flow of nitrogen through the annulus sufficient to prevent the flow of air and moisture into the annular space. Note that in practice this is difficult to do.

When replacing Outer Vessel Pressure Safety Element O-rings with the Orca empty and warm (ambient temperature), break the annular vacuum with dry nitrogen according to the following procedure:

1 . Break the Orca vacuum in a slow, controlled manner so as not to damage the insulation materials in the annular space .

A gauge reading in inches of mercury vacuum (“ HG vacuum) attached to the vacuum space is required .

VV-1 Vacuum

Pumpout Valve



One way to do this is to connect the gauge to a tee off of the outlet of the VV-1 Vacuum Pumpout Valve . When breaking the vacuum to nitrogen, it is recommended that the introduction of dry nitrogen (from 30” HG vacuum to 0” vacuum, or 1 Atm .) be done slowly, taking two hours minimum, at a rate of 4” HG vacuum (maximum) in fifteen minutes. Below 30” HG vacuum there is very little flow in the annular space, but from 30” HG vacuum up to 0” HG vacuum there is much more flow, and if not controlled (or restrained) it could damage the insulation .

2 . Lift off the Outer Vessel Pressure Safety Element cover and remove the old O-ring . Be careful not to scratch the groove surfaces .

3 . Carefully clean the O-ring grooves, the sealing surface of the cover and the new O-ring .

4 . Coat the new O-ring with a very thin layer of vacuum grease, place the O-ring in the groove, then install the Outer Vessel Pressure Safety Element cover concentric with the grooved flange. Hold the cover down until there is enough vacuum to hold it in place .

Note: A very slight positive purge of dry nitrogen should be maintained on the annular space while the vacuum is broken in order to keep out moisture. If moisture gets into the annular space, it can take a very long time to vacuum pump it out, and the high vacuum necessary for the desired thermal performance of the insulation cannot be obtained with moisture in the annular space.


Troubleshooting

General Troubleshooting Information

Excessing Venting

Excessive gas venting due to high inner vessel pressure can result if the unit is used too infrequently, if the annular vacuum is inadequate or if the V-16 Saturation Valve is left open .

Primary and Secondary Pressure Vessel Safety Relief Valves

If the secondary Pressure Vessel Safety Relief Valve, SV-1C, relieves due to over pressure, it indicates that the inner vessel pressure has gone higher than the pressure settings on the primary Pressure Vessel Safety Relief Valves, SV-1A and SV-1B . This is not probable if SV-1A and SV-1B are operating correctly .

Note that:

• The primary Pressure Vessel Safety Relief Valves, SV-1A and SV-1B, are set to open at pressures greater than 160 psi [11 bar] .

• The secondary Pressure Vessel Safety Relief Valve, SV-1C, is set to open at pressures greater than 240 psi [16 .5 bar] .




Relief Valve


Relief Valve

80 Troubleshooting Operation Manual – HL-6200 LNG Orca

Saturation Heat Exchanger

The saturation heat exchanger system is a manual system controlled by throttling the V-16 Saturation Valve . If the pressure in the unit climbs to 150 psi because of the pressure building system, close V-16 .

If the Orca pressure is low and V-16 is open, it is possible that the Saturation Outlet Check Valve, CV-2, is stuck closed . This would be indicated by frosting of V-16 and no (or limited) frosting of CV-2 and the pressure build return piping . The Saturation Heat Exchanger, VAP-1, probably will not be frosted if flow is stopped or restricted . (Also refer to Appendix B – Process and Instrumentation Diagram .)

Vacuum Thermocouple and Isolation Valve

The VV-2 TC Isol (isolation) Valve should be kept closed except when reading the vacuum gage, as the joint between the TC-1 Vacuum Thermocouple and the VV-2 TC Isol Valve is a potential source of leakage . It’s recommended that you read the vacuum first with the VV-2 TC Isol Valve closed, then open the VV-2 TC Isol Valve and read the vacuum again . A drop in indicated pressure when the VV-2 TC Isol Valve is opened shows a leak between the TC-1 Vacuum Thermocouple and VV-2 TC Isol Valve . (A leak in the TC-1 Vacuum Thermocouple would act the same way but is less likely .)

If there is a leak between the TC-1 Vacuum Thermocouple and VV-2 TC Isol Valve, re-seal the threaded joint . (Refer to the Maintenance and Repair/Replacing the Vacuum Thermocouple, TC-1 subsection .)

A faulty TC-1 Vacuum Thermocouple will not move off atmosphere when read . The TC-1 Vacuum Thermocouple contains two circuits; the heater filament and the thermocouple. Conceivably either one can break, but the common failure is the heater filament. If the filament is broken or burned out, the TC-1 Vacuum Thermocouple cannot be “zero set” . The thermocouple circuit can be checked with a continuity meter .

A leak across the seat of the VV-2 TC Isol Valve, whether from not being closed tight or from a faulty VV-2 TC Isol Valve, will be indicated by a vacuum between the VV-2 TC Isol Valve seat and the plug outside the VV-2 TC Isol Valve . If this is found, after evacuation, check the rise in the insulation pressure overnight with the plug omitted . If there is a measurable rise, reconnect the vacuum pump, pump against the closed Valve and check the rise in pressure for a similar period . If the pressure rises with the outside of the VV-2 TC Isol Valve at atmospheric pressure and does not rise with the outside of the VV-2 TC Isol Valve evacuated, there is a leak across the VV-2 TC Isol Valve seat and the VV-2 TC Isol Valve should be replaced .

If a leak is suspected between the VV-2 TC Isol Valve and the jacket, pack thread sealant or vacuum putty around the joint . If this provides a temporary cure, make a more permanent cure at the earliest opportunity .



Vacuum Thermocouple

81TroubleshootingOperation Manual – HL-6200 LNG Orca

pressure vessel safety relief valves

LI-1 Inner Vessel Level Indicator and Associated Valves

The LI-1 Inner Vessel Level Indicator senses the difference in pressure between the top of the inner vessel (Gas Phase line “G”) and the bottom of the inner vessel (Liquid Phase line “D”) . The LI-1 Inner Vessel Level Indicator displays this pressure differential as IN. H2O (inches of water) which the Operator can convert to gallons, pounds or cubic feet of gas by using the Liquid Level chart on the inside of the rear enclosure door . Note that anything that produces a false differential pressure at the LI-1 Inner Vessel Level Indicator, or which upsets the assumptions on which the calculations are based, will produce an incorrect liquid level reading .

Leaks in the lines to the LI-1 Inner Vessel Level Indicator will produce a false differential pressure. With no flow, the gas pressure in a line is the same at the inner vessel end and the outer vessel end, as it should be . If there is a leak in the piping outside the vacuum jacket, there is flow from the inner vessel to the leak, and where there is flow there is always a pressure drop . If there is a leak in the gas side piping, the result is a lower than true pressure at the gas side of the LI-1 Inner Vessel Level Indicator, while the liquid side pressure is true . This means the LI-1 Inner Vessel Level Indicator feels a greater pressure difference than it should and will read higher than it should .

If there is a leak in the liquid side piping, the same thing happens in reverse . The pressure difference and LI-1 Inner Vessel Level Indicator readings are lower than they should be . In addition, liquid is allowed to move farther out than normal in the line in the insulation space . Since this line is rising (in the trap), the net height of liquid, i .e ., the vertical height from the liquid surface in the LI-1 Inner Vessel Level Indicator line to the liquid surface in the inner vessel, is reduced, causing a further drop in the reading .

A significant leak in the liquid side LI-1 Inner Vessel Level Indicator piping will cause frost to appear where the line leaves the vacuum jacket .

If the V-10 LI-1 Equalization Valve is partially open, the differential pressure on the LI-1 Inner Vessel Level Indicator will be partially eliminated by flow through V-10, resulting in a low reading or no reading at all .

It is possible, although not common, for the LI-1 Inner Vessel Level Indicator itself to fail . If the LI-1 Inner Vessel Level Indicator goes to 0 inches (or millimeters) water column when the V-11 LI-1 Vapor Phase and V-12 LI-1 Liquid Phase Valves are closed and V-10 is open, the LI-1 Inner Vessel Level Indicator is probably working correctly . If it will not zero it should be replaced .

One assumption in the calibration calculations is the position of the liquid surface in the Liquid Phase line “D” . There is no way of determining this precisely . If the wrong position is assumed, the readings will be off by a constant and usually small amount at all liquid levels .

When pressure in the inner vessel is changed quickly, the position of the liquid in the line will change and cause the LI-1 Inner Vessel Level Indicator reading to change . An increase in pressure causes a decrease in reading and vice versa . This condition corrects itself in a short time .

Another assumption in the calculations is the density of the liquid . This is shown on the liquid level chart on the inside of the rear enclosure door . (Also refer to Appendix C – Liquid Level Chart .)

LI-1 Inner Vessel

Level Indicator


Valve


Valve


Valve


Troubleshooting Table

Problem Cause CorrectionA primary pressure vessel safety relief valve (SV-1A or SV-1B) pops.

Excessive Orca pressure. See the “Excessive Orca pressure” entry in the Problem column below.

Faulty primary pressure vessel safety relief valve.

Examine and replace the primary pressure vessel safety relief valve(s) if necessary. (Refer to the Replacing a Safety Valve subsection in the Maintenance and Repair manual section.)

The secondary pressure vessel safety relief valve (SV-1C) pops.

Excessive Orca pressure. See the “Excessive Orca pressure” entry in the Problem column below.

Faulty primary pressure vessel safety relief valve.

Examine and replace the pressure vessel safety relief valve(s) if necessary. (Refer to the Replacing a Safety Valve subsection in the Maintenance and Repair manual section.)

Faulty secondary pressure vessel safety relief valve.

Examine and replace the secondary pressure vessel safety relief valve if necessary. (Refer to the Replacing a Safety Valve subsection in the Maintenance and Repair manual section.)

Excessive Orca pressure (150 psi or higher). Note that typical Orca pressure is approximately 100 psi.

The V-16 Saturation Valve has been left open.

Close the V-16 Saturation Valve.

Inadequate annular vacuum. Refer to the Annular Vacuum Checking Procedure and the Re-evacuating the Orca subsections in the Maintenance and Repair manual section.

The Inner Vessel Pressure Indicator(s) is/are not reading correctly.

Check and replace the Inner Vessel Pressure Indicator(s) if necessary. (Refer to the Replacing an Inner Vessel Pressure Indicator (PI-1A or PI-1B) subsection in the Maintenance and Repair manual section.)

Excessive venting from vehicle tanks into the Orca.

Fill more vehicle tanks and add cold LNG to the Orca more often.

Orca pressure is low. The V-16 Saturation Valve is closed. Open the V-16 Saturation Valve.The Saturation Outlet Check Valve (CV-2) is stuck closed.

Repair or replace CV-2.

The Inner Vessel Pressure Indicator(s) is/are not reading correctly.

Check and replace the Inner Vessel Pressure Indicator(s) if necessary. (Refer to the Replacing an Inner Vessel Pressure Indicator (PI-1A or PI-1B) subsection in the Maintenance and Repair manual section.)

83TroubleshootingOperation Manual – HL-6200 LNG Orca

Problem Cause CorrectionAnnular vacuum reading.

The VV-2 TC (thermocouple) Isol (isolation) Valve is closed but there’s a leak at the joint.

Refer to the Vacuum Thermocouple and Isolation Valve subsection.

Bad TC-1 Vacuum Thermocouple. Replace the TC-1 Vacuum Thermocouple. (Refer to the Replacing the Vacuum Thermocouple, TC-1 subsection in the Maintenance and Repair manual section.)

The VV-2 TC Isol Valve is not closed tight or is leaking.

Refer to the Vacuum Thermocouple and Isolation Valve subsection.

The annular space needs to be re-evacuated.

Refer to the Re-evacuating the Orca subsection in the Maintenance and Repair manual section.

There is a leak between the VV-2 TC Isol Valve and the jacket.

Refer to the Vacuum Thermocouple and Isolation Valve subsection..

The O-ring on a Outer Vessel Pressure Safety Element, SD-2, is leaking.

Replace the O-ring. (Refer to the Replacing the O-ring on the Outer Vessel Pressure Safety Element, SD-2 subsection in the Maintenance and Repair manual section.)

The LI-1 Inner Vessel Level Indicator reads too high.

There is a leak in the vapor side piping. Find and repair the leak. (Refer to the LI-1 Inner Vessel Level Indicator and Associated Valves subsection.)

The LI-1 Inner Vessel Level Indicator needs to be zeroed.

Zero the LI-1 Inner Vessel Level Indicator. (Refer to the Zeroing the Inner Vessel Level Indicator (LI-1) subsection in the Maintenance and Repair manual section.)

The LI-1 Inner Vessel Level Indicator is out of calibration.

Contact the Gauge manufacturer for calibration instructions.

Faulty LI-1 Inner Vessel Level Indicator. Replace the LI-1 Inner Vessel Level Indicator. (Refer to the Replacing the Inner Vessel Level Indicator (LI-1) subsection in the Maintenance and Repair manual section.)

The LI-1 Inner Vessel Level Indicator reads too low.

The V-10 LI-1 Equalization Valve is not closed.

Close the V-10 LI-1 Equalization Valve.

There is a leak in the liquid side piping. Find and repair the leak. (Refer to the LI-1 Inner Vessel Level Indicator and Associated Valves subsection.

The LI-1 Inner Vessel Level Indicator needs to be zeroed.

to the Zeroing the Inner Vessel Level Indicator (LI-1) subsection in the Maintenance and Repair manual section.)

The LI-1 Inner Vessel Level Indicator is out of calibration.

Contact the Gauge manufacturer for calibration instructions.

Faulty LI-1 Inner Vessel Level Indicator. Replace the LI-1 Inner Vessel Level Indicator. (Refer to the Replacing the Inner Vessel Level Indicator (LI-1) subsection in the Maintenance and Repair manual section.)

An Inner Vessel Pressure Indicator (PI-1A or PI-1B) reads too high.

Faulty Inner Vessel Pressure Indicator. Check and replace the Inner Vessel Pressure Indicator if necessary. (Refer to the Replacing an Inner Vessel Pressure Indicator (PI-1A and PI-1B) subsection in the Maintenance and Repair manual section.)


Problem Cause CorrectionAn Inner Vessel Pressure Indicator (PI-1A or PI-1B) reads too low.

The V-11 LI-1 Vapor Phase Valve (PI-1A) or V-14 PI-1B Shutoff Valve (PI-1B) is closed.

Open the appropriate valve.

There is a leak in the gauge piping. Find and repair the leak.Faulty Inner Vessel Pressure Indicator. Check and replace the Inner Vessel Pressure

Indicator if necessary. (Refer to the Replacing an Inner Vessel Pressure Indicator (PI-1A and PI-1B) subsection in the Maintenance and Repair manual section.)

A pressure vessel safety relief valve or thermal safety valve pops.

Liquid or very cold gas was trapped between closed valves.

None. The pressure vessel safety relief valve or thermal safety valve is operating correctly.

Faulty pressure vessel safety relief valve or thermal safety valve.

Replace the safety valve. (Refer to the Replacing a Safety Valve subsection in the Maintenance and Repair manual section.)

The AOV-1 Air-operated Dispense Valve will not open.

The Emergency Air Shutoff Switch is set to the CLOSED position.

Set the Emergency Air Shutoff Switch to the OPEN position.

There is an air leak in the line to the AOV-1 Air-operated Dispense Valve. Note that the AOV-1 will fail to closed.

Check the compressed air lines and connections for air leaks and correct as necessary.

Inadequate compressed air supply. Check the compressed air supply from the air compressor and repair as necessary.

The off-load pump doesn’t catch prime.

The hose is restricting flow. Make sure the hose is at least 3” in diameter and is no longer than 13 feet.

The hose from the Tanker to the Orca has a sag or dip that is creating a liquid trap.

Run the hose straight from the Tanker to the Orca.

The OFF-LOAD TEMP. OK light on the Transport Off-load Control Panel Pendant is not on.

Insufficient cool-down time. (This typically takes 25-35 minutes.)

Open the V-1 Off-load Inlet Valve and V-2 Off-load Return Valve to allow the liquid flow to cool the off-load pump.

Fuel won’t dispense. Vehicle tank pressure too high. Vent the vehicle tank back to the Orca until the vehicle tank pressure is 100-120 psi.

The trailer brakes won’t release when the rear enclosure doors are closed.

There is an air leak in trailer brake circuit. Check the compressed air lines and connections for air leaks and correct as necessary.

The Anti-tow Valve mounted at the top of the rear enclosure is not operating correctly and is not allowing compressed air to the trailer brakes to release the brakes.

Check the Anti-tow Valve and air lines and repair/replace as necessary.

A1Operation Manual – HL-6200 LNG Orca

Appendix A – MSDS

A2 Appendix A – MSDS Operation Manual – HL-6200 LNG Orca

B1Operation Manual – HL-6200 LNG Orca

Appendix B – Process and Instrumentation Diagram

SCALE

DRAWINGNUMBER

SHEET

C-20618765

TITLER

DRAWNBY

CHK'DBY

MFG.SERV.

PROJ.ENGR.

MFG.ENGR.

QUAL.CONT.

PARTNUMBER

DRAWINGNUMBER

R

THIRD ANGLE PROJECTIONAPPROVED DATE

MGS 7/23/12 C 15230 RV'S WERE ROCKWOOD MMK 2/13/13

Material RequiredSEE B.O.M. UNLESS

OTHERWISE STATED

GJS 8/16/12 B 15176 AS BUILT CHANGES MGS 12/11/12CT 9/6/12 A - CHANGE PCV-2 P/N MGS 10/9/12

CPL 8/21/12 REV ECR NO DESCRIPTION BY DATEVISIT US AT CHARTINDUSTRIES.COM RC 8/17/12

Innovation. Experience. Performance. Distribution & Storage, New Prague Operations

OEM PARTS AT CHARTPARTS.COM KJR 8/16/12THE MATERIALS AND INFORMATION, INCLUDING THEPRINCIPLES OF DESIGN CONTAINED IN THIS PRINT,IS THE EXCLUSIVE PROPERTY OF CHART INC., AND

IS CONFIDENTIAL AND PROPRIETARY INFORMATION.THIS INFORMATION MAY NOT BE REPRODUCED,

COPIED, OR LOANED, IN PART OR IN WHOLE, NORIS THE INFORMATION TO BE RELATED TO ANY PARTY

WITHOUT CHART'S PRIOR WRITTEN CONSENT.

UNLESS OTHERWISE SPECIFIEDDIMENSIONS ARE IN INCHES.TOLERANCES:FRACTIONS ± 1/8ANGLES ± 1 °2 PLACE DECIMALS ± N/A3 PLACE DECIMALS ± N/A

P&ID HL-6200 ORCA LNGW/ OFFLOAD PUMP

C-20618765 Rev CFULL 20618765 1 OF 4

TAG DEFINITION CHART PN VENDOR INFORMATION SIZEAOV-1 AIR OPERATED VALVE, DISPENSE 15062327 WORCESTER# C4466PMBW10-15L39SN 1"NPS

V-1 VALVE, OFFLOAD INLET 10673145 WORCESTER #3"C5166PT-150 3"NPSV-2 VALVE, OFFLOAD RETURN 1717211 WORCESTER #C4466PMBWV60 W/EXT 1"NPSV-5 VALVE, VAPOR VENT 10927192 REGO #S-232HCB-8WA B31.3 1"NPSV-8 VALVE, VAPOR SAMPLE 1713202 REGO #T9453 REGO QUOTE 3/8"FPTV-10 VALVE, LI-1 EQUALIZATION 11701435 WHITEY #SS-1VS4-SC-11 1/4"ODTV-11 VALVE, LI-1 VAPOR PHASE 11701443 WHITEY #SS-1VS4-A-SC11 1/4"ODTV-12 VALVE, LI-1 LIQUID PHASE 11701443 WHITEY #SS-1VS4-A-SC11 1/4"ODTV-13 VALVE, PUMP DISCHARGE GAUGE ISOL 11701443 WHITEY #SS-1VS4-A-SC11 1/4"ODTV-14 VALVE, PI-IB SHUTOFF 11701435 WHITEY #SS-1VS4-SC-11 1/4"ODTV-16 VALVE, SATURATION 1718772 REGO #BK9412T-PC 1-1/2"NPSV-18 VALVE, FULL TRYCOCK DOT 1713202 REGO #T9453 REGO QUOTE 3/8"FPTV-19 VALVE, FULL TRYCOCK 90% 1713202 REGO #T9453 REGO QUOTE 3/8"FPTV-20 VALVE, OFFLOAD INLET DRAIN 1714561 REGO #S-232HCB-4WA B31.3 1/2"NPSV-21 VALVE, OFFLOAD RETURN DRAIN 1714561 REGO #S-232HCB-4WA B31.3 1/2"NPSV-22 VALVE, VENT RETURN ISOL 1718772 REGO #BK9412T-PC 1-1/2"NPSV-31 VALVE, VAPOR PHASE ISOL 1711862 NUPRO #B-4JNA1-KL B31.3 1/4"MPT/ 1/4"ODTV-32 VALVE, LIQUID PHASE ISOL 1711862 NUPRO #B-4JNA1-KL B31.3 1/4"MPTV-33 VALVE, SUMP DRAIN 1713202 REGO #T9453 REGO QUOTE 3/8"FPTV-40 VALVE, SAT. FORCE FEED 1713202 REGO #T9453 REGO QUOTE 3/8"FPTV-44 VALVE, VENT WATER DRAIN 1713202 GODDARD #DGN-3T SERIES 270 NON 3/8"NPTV-45 VALVE, GENERATOR 12976211 WORCESTER #C4466PMSE-1/2" 1/2"FPTVV-1 VALVE, VACUUM PUMPOUT 10562120 1-1/2PS BW CAST 316L GRINNELL# 1-1/2"FPTVV-2 VALVE, TC ISOL 10482381 HOKE 4111L2B BRS 1/8"MPTX1/8"FPTBC-1 CONNECTION, BREAKAWAY DISPENSING 11187122 CHART SUPPLIED 1"NPTBC-2 CONNECTION, BREAKAWAY DISPENSING 20645216 CHART SUPPLIED 1"NPTX1/2"NPTCV-1 CHECK VALVE, OFFLOAD DISCHARGE 15094361 HEROSE #05416.4048.0002 1-1/2"NPSCV-2 CHECK VALVE, SATURATION OUTLET 1712152 POWELL #560Y CL 200 MSS-SP80 1"NPSCV-4 CHECK VALVE, HOSE DRAIN 11051090 GENERANT CV-503B-T-5 O2 CLN 1/2"FPTCV-7 CHECK VALVE, RECIRCULATION 11889589 GENERANT CV-373B-T-8-X O2 CLN 3/8"FPT

CV-8A CHECK VALVE, TOP FILL 11721655 FEI#M507J MILWAUKEE BRAND 1-1/2"NPSCV-8B CHECK VALVE, TOP FILL 11721655 FEI#M507J MILWAUKEE BRAND 1-1/2"NPSCV-9A CHECK VALVE, BOTTOM FILL 1712152 POWELL #560Y CL 200 MSS-SP80 1"NPSCV-9B CHECK VALVE, BOTTOM FILL 1712152 POWELL #560Y CL 200 MSS-SP80 1"NPSDC-1 CONNECTION, DISPENSE 11486229 JC CARTER # 50E701-1 50GPM LNGDC-3 CONNECTION, OFFLOAD INLET 4016932 3"FNPT ACME #450-003-30 CGAV-6 3" CGADC-4 CONNECTION, OFFLOAD RETURN 4016932 3"FNPT ACME #450-003-30 CGAV-6 3" CGA

DC-5A CONNECTION, VENT 10538867 MACRO-TECH #11175DC-5B CONNECTION, RECIRCULATION 11728099 JC CARTER #62050 3 HOLE MT 3/4"FPTDP-1 TRANSMITTER, FLOW METER 11495862 SIEMENS 7MF4433-1FA22-1NC1-B21DT-1 DENSITY TRANSMITTER 11207980 TRANSMITTER LEVEL 4-20MA 24VDCLI-1 LEVEL INDICATOR, INNER VESSEL 14323716 MIDWEST #116-0040 3/4" CBM 1/4"FPTM-1 METER, FLOW DISPENSE FL1171030 CHART METER ELEMENT

PI-1A PRESSURE INDICATOR, INNER VESSEL 11702112 AMETEK U.S. GAUGE #1903 B31.3 1/4"MPTPI-1B PRESSURE INDICATOR, INNER VESSEL 20652327 AMETEK U.S. GAUGE #1903 B31.3 1/4"MPTPI-2 PRESSURE INDICATOR, PUMP DISCHARGE 11702121 AMETEK U.S. GAUGE #1903 B31.3 1/4"MPTPI-3 OFFLOAD PUMP DISCHARGE 11702112 AMETEK U.S. GAUGE #1903 B31.3 1/4"MPTPT-1 PRESSURE TRANSMITTER, PUMP DISCHARGE 15071098 SIEMENS 7MF4033-1EA10-1NC6-Z-PT-2 VESSEL PRESSURE TRANSMITTER 11495854 SIEMENS 7MF4033-1DA10-1NC1-A02RR-1 FLOW RESTRICTOR, RECIRCULATION 14808318 T304 SA240

RTD-1 RESISTANCE TEMPERATURE DEVICE 10929382 BURNS #200A10B5A300/LY010C10S-2 STRAINER, OFFLOAD INLET 10730859 CHART SUPPLIED 1-1/2"NPSS-3 STRAINER, VENT 11529090 UNITED BRASS #200WSCH 600# WOG 1/2"NPS

SD-2 PRESSURE SAFETY ELEMENT, OUTER VESSEL 10899110 CHART SUPPLIED SV-1A SAFETY RELIEF VALVE, PRESSURE VESSEL 20662777 HEROSE #06388.2314.6040 1-1/2"MPTX2"FPTSV-1B SAFETY RELIEF VALVE, PRESSURE VESSEL 20662777 HEROSE #06388.2314.6040 1-1/2"MPTX2"FPTSV-1C SAFETY RELIEF VALVE, PRESSURE VESSEL 20662728 HEROSE #06388.2314.6040 1-1/2"MPTX2"FPTTC-1 VACUUM THERMOCOUPLE 4210049 HASTINGS 1415671S #DV-6

A TOP FILL 1-1/2"PSB BOTTOM FILL 1-1/2"PSC DOT TRYCOCK 3/8"PSD LIQUID PHASE 1/4"PSE 90% TRYCOCK 3/8"PS F PUMP VENT 1-1/2"PSG GAS PHASE 1/4"PSH PUMP FEED 2-1/2"PSJ VENT 1-1/2"PS

TAG DEFINITION CHART PN VENDOR INFORMATION SIZETSV-5 THERMAL SAFETY, OFFLOAD 1811261 SWAGELOK #SS-4CPA2-150 316SS 1/4"MPTTSV-6 THERMAL SAFETY, OFFLOAD 1811261 SWAGELOK #SS-4CPA2-150 316SS 1/4"MPTTSV-7 THERMAL SAFETY, VENT 1811261 SWAGELOK #SS-4CPA2-150 316SS 1/4"MPTP-1 DISPENSING PUMP 20575286 ACD #59435-1 TC-34 (KA)P-2 OFFLOAD PUMP 15098282 ACD # TC-30 1.5X2.5X10 15HP 2-1/2"NPSTRAN-1 TRANSFER HOSE, DISPENSE 15072832 1"TRAN-2 TRANSFER HOSE, DISPENSE 15072824 1/2"TRAN-3 TRANSFER HOSE, DISPENSE 20624340 1"TRAN-4 TRANSFER HOSE, DISPENSE 20624340 1"VAP-1 SATUATION HEAT EXCHANGER20607378 CHART SUPPLIED 1"ODVAP-2 WARMING COIL 11044181 CHART SUPPLIED 1-1/4"ODTTT-1 P-2 PUMP 20546195 BURNS #200A10A14S030/EN80TCM03LT-1 VESSEL LEVEL TRANSMITTER 11495862 SIEMENS 7MF4433-1FA22-1NC1-B21PCV-1 GENERATOR REGULATOR 10555309 CASH #12290--0050 TYPE B 1/2"NPSPCV-2 GENERATOR REGULATOR 20551326 AMERICAN METER #KMB1A3B1A11A1 1"NPSGEN-1 GENERATOR 15085844 BALDOR IGLC35 39KVA

M-1

V-11LI-1

PI-1A

V-10

V-12

P-1 / SUMP ASSY

V-18

SD-2

TRAN-1

V-31

V-32

V-33

V-13PI-2

CV-4RTD-1

AOV-1

V-16VAP-1

CV-2

CV-8A

V-40

DC-1

DP-1

VV-2 TC-1

VV-1 CV-7

BC-1

RR-1

PI-1B

CV-8B

DC-5B

DC-5A

V-19

DT-1

PT-1

SV-1A SV-1B SV-1CV-5

V-8

V-44

DC-3

CV-1

V-1

V-2

DC-4

V-22

TSV-5

TSV-6

V-20

V-21

CV-9B

S-2

S-3

P-2

CV-9A

AE

FG

C

D

B

H

J

BC-2

TRAN-2

PI-3

TT-1

LT-1

PT-2

PCV-1V-45VAP-2PCV-2GEN-1

TSV-7

V-14

TRAN-3

TRAN-4

B2 Appendix B – P&ID Operation Manual – HL-6200 LNG Orca

C-20618765DRAWINGNUMBER

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VISIT US AT CHARTINDUSTRIES.COM APPROVED DATEInnovation. Experience. Performance.

Distribution & Storage, New Prague OperationsOEM PARTS AT CHARTPARTS.COM MGS 8/20/12

THE MATERIALS AND INFORMATION, INCLUDING THEPRINCIPLES OF DESIGN CONTAINED IN THIS PRINT,IS THE EXCLUSIVE PROPERTY OF CHART INC., AND




UNLESS OTHERWISE SPECIFIEDDIMENSIONS ARE IN INCHES.TOLERANCES:FRACTIONS ± 1/8ANGLES ± 1 °2 PLACE DECIMALS ± NA3 PLACE DECIMALS ± NA


C-20618765 Rev C1/16"=1" 20618765 2 OF 4

DP-1

RTD-1

LT-1 PT-1

DT-1

NOTES:1. PI-IB AND V-14 TAGS TO BE ATTACHED TO GAUGE AT THE FRONT OF TANK ROADSIDE.

SD-2

VAP-1

CV-8A CV-8B VV-2TC-1

RR-1 V-31 V-32CV-7

PI-2

V-8

V-18

V-19

V-33

V-40

V-13

V-12

LI-1

V-10V-11PI-1AM-1P-1

V-16

S-3

TSV-7

V-22

CV-2

CV-9B

CV-9A

TRAN-3BC-2

TRAN-2DC-5A

CV-4

DC-5B

AOV-1 TRAN-4BC-1

TRAN-1DC-1

V-44 SV-1C SV-1BV-5 SV-1A

FRONT

VV-1

PT-2

B3Appendix B – P&IDOperation Manual – HL-6200 LNG Orca


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C-20618765 Rev C13/320"=1" 20618765 3 OF 4

PCV-1

V-45

VAP-2

PCV-2

GEN-1

P-2

V-1

TSV-5

TSV-6

V-20

V-21

V-2

DC-4

DC-3

S-2

TT-1

PI-3 CV-1

B4 Appendix B – P&ID Operation Manual – HL-6200 LNG Orca


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328-3/8 BTL OAL

556-13/16

102

140-5/8









C-20618765 Rev C9/320"=1" 20618765 4 OF 4

C1Operation Manual – HL-6200 LNG Orca

Appendix C – Liquid Level Chart

LIQUID LEVELLIQUID LEVELQM hMethane

Li id W i htIn H O Liquid Weight Gas (CU Ft)In H2O (Gallons) (Pounds)Gas (CU Ft)

(Gallons) (Pounds)0 0 0 00 0 0 00.4 0 253 6,093,1 39 383 9 2171 39 383 9,2172 135 697 16 7932 135 697 16,7933 262 1,116 26,9013 262 1,116 26,9014 413 1,616 38,940, ,5 585 2 181 52 5585 585 2,181 52,5586 773 2 801 67 5006 773 2,801 67,5007 975 3,468 83,5697 975 3,468 83,5698 1 189 4 175 100 6018 1,189 4,175 100,6019 1 414 4 916 118 4559 1,414 4,916 118,45510 1 647 5 686 137 00410 1,647 5,686 137,00411 1,888 6,479 156,13211 1,888 6,479 156,13212 2 134 7 293 175 73212 2,134 7,293 175,73213 2 385 8 122 195 70113 2,385 8,122 195,70114 2 640 8 962 215 94214 2,640 8,962 215,94215 2,897 9,809 236,361, , ,16 3 155 10 660 256 86416 3,155 10,660 256,86417 3 413 11 510 277 36017 3,413 11,510 277,36018 3,669 12,357 297,75718 3,669 12,357 297,75719 3,923 13,195 317,961, , ,20 4 174 14 022 337 87820 4,174 14,022 337,87821 4 420 14 832 357 40921 4,420 14,832 357,40922 4,659 15,623 376,45122 4,659 15,623 376,45123 4 891 16 388 394 89723 4,891 16,388 394,897, , ,24 5 114 17 124 412 62824 5,114 17,124 412,62825 5 327 17 825 429 51625 5,327 17,825 429,51626 5,527 18,485 445,41626 5,527 18,485 445,41627 5 712 19 097 460 16027 5,712 19,097 460,16028 5 881 19 652 473 54428 5,881 19,652 473,54429 6 029 20 140 485 30229 6,029 20,140 485,30230 6,151 20,545 495,054, , ,31 6 240 20 838 502 12831 6,240 20,838 502,12832 6 268 20 930 504 34732 6,268 20,930 504,347

HL 6200HL‐6200(30 i S t ti P )(30 psig Saturation Pressure)

hl-6200 lng orca - chart...

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