Common Troubles and Troubleshooting for LNG System

The LNG fuel system consists of the cylinder (fluid reservoir), vaporizer, line regulator, buffer tank, pressure
building pipeline and other systems.
The LNG cylinder (fluid reservoir) is a cryo-insulation pressure vessel which can be used to multiply fill a gas.
With the double-layer vacuum insulation structure, the reservoir consists of the inside liner, housing, insulating layer,
valves and etc. The natural gas is stored in the low-temperature low-pressure vacuum insulation reservoir with
the form of liquid-state, the inside temperature of the fluid reservoir is generally between -138 and -162,
and the normal operating pressure of the cylinder shall be no more than 1.89MPa.
Vaporizer: The LNG gas shall be vaporized by the vaporizer to the CNG gas after its temperature rises, and
then the CNG gas is supplied to the engine. Much more heat will be absorbed during vaporization. The
vaporizer uses the engine circulating coolant to heat and vaporize the liquefied natural gas (LNG), and thus
make the natural gas meet the engine operating temperature and flowrate requirements.
The main function of the line regulator is to decrease the pressure of natural gas after vaporized by the
vaporizer and lower the pressure down to the set pressure of the pressure stabilizer so as to ensure that the
pressure of gas entering into the engine meets the operating requirement.
The function of the buffer tank is to store a certain amount of gas in the tank, and provide the additional gas
consumption if the higher gas consumption (e.g., high power required) is required while the vaporized gas is
insufficient, which avoids the shortage of gas supply.
For the LNG supply system, the gas supply and pressure will directly affect the engine performance and its
operating reliability.
The schematic diagram of a LNG system:

Page 1 of 7 pages

In the LNG system, the symbol, name and function description for its functional parts are as follows:
Symbol

Chinese name model

Function description

C1

The filling connection DJK-25B

The device used while filling the LNG fluid

C2

The vent connection DHK-10A

The special connection for discharging the gas

Vv

Vent valve (globe) DJ-10P6-S2

It is used to exhaust and reduce the pressure inside the cylinder

while filling the LNG fluid. Bleed the pressure inside the cylinder
in case of emergency.

Vu

Use valve (globe) DJ-10P-S1

It is used to supply the LNG or cut off the supply

Va

Vaporizer

Convert the LNG to the CNG

FCv

The filling check valve DH-15C

It is used to prevent the outflow of LNG filled into the cylinder

DCv

The delivery check valve DH-06

It is a small check valve which is used to prevent the backflow of

the high-pressure gas

Er

Economizer regulator

It is used to preferentially use the gas and thus ensure the pressure
inside the cylinder. The set value 0.9MPa

Ef

Excess flow valve

P1

Cylinder Pressure Gauge

Display the inside pressure of the cylinder

P2

Piping Pressure Gauge

Display the pressure of the buffer tank

PBr

Pressure Building Regulator

DYJ-06A

DL-06-10

DYS-06A1

It is used to prevent the excessive outflow of the LNG gas from the
cylinder when the external pipeline is loss of pressure.

It is used to control the pressure inside the cylinder during pressure

building, with the set value of 0.80MPa
By vaporizing the LNG to the CNG, it is used to increase the
pressure inside the cylinder

Pr

Pressure Building Coil

Pv

Pressure Building Valve

LG

Liquid Fuel Level Gauge

It is used to display the liquid capacity inside the cylinder

Svp

Primary Safety Valve

CRVP-253B-K-275

It is used to control the safety pressure inside the cylinder. The set
value 1.89MPa

Svs

Secondary Safety Valve

CRVP-253B-K-413

In case of the primary safety valve failure, it is used to control the

pressure inside the cylinder and ensure the safety of the cylinder.
The set value 2.85MPa

LSv

Line Safety Valve

CRVP-253B-K-348

It is used to release the excessive pressure and thus protect the

safety of the line system. The set value 2.4MPa

LRe

Line Regulator
DYS-20 or DYS-15C

It is also called the pressure stabilizer, which is used to regulate the

pressure to the desired pressure. The set value 0.86MPa

Cb

Convert Box

It is used to convert the analog signal to the digital signal output.

SV

Solenoid valve

It is used to control opening and closing of a valve through the

power supply.

DJ-10P5

It is used to control whether the pressure building is required.

Here, the operating principle of the LNG system isn't described in details.
Now, the common trouble diagnosis, possible cause analysis and troubleshooting for the LNG system are
summarized as follows:

Page 2 of 7 pages

Common Troubles and Troubleshooting for LNG System:

Trouble

Underpowered

Underpowered

LNG system appearance phenomena

description

The cylinder pressure normal;

The vaporizer surface condensed,
frosted;
The buffer tank pressure low;
(shortage of gas supply)

The cylinder pressure continuously

decreases;
And the pressure building coil isn't
frosted;
The buffer tank pressure can't reach
the specified value;
(Not pressure building)

Inspection Method

Possible Cause

Troubleshooting

1. Check whether the gas supply

pipeline is leaked, broken; and
whether it is frosted, condensed, or
frozen

The pipeline leakage, results in the low

engine gas-supply pressure

Tighten the pipeline leakage connector;

Since the materials of connection and valve are
different and the coefficient of thermal
expansion is varied, the leakage easily occurs at
the beginning of driving.

2. Check whether the water inlet and

outlet pipes of vaporizer are crushed,
flattened or leaked

Shortage of vaporizer heat supply, results in

the insufficient vaporization capacity

Check whether the water inlet and outlet pipes

are leaked; whether there is the crushed flat,
deformation, and the reduction of water
flowrate; and whether there is any deterioration;

3. Check whether the engine coolant

temperature and water pump function
are normal, and check the flowrate

Shortage of vaporizer heat supply, results in

the insufficient vaporization capacity

Replace the water pump

4. Check whether there is any leakage

inside the vaporizer.
Whether the gas flows out from the
expansion tank.

The internal leakage inside the vaporizer

results in the shortage of gas supply

Replace the vaporizer

5. Low ambient temperature, the

engine coolant temperature doesn't
reach 60

When the ambient temperature is below 0,

the engine coolant temperature reaches 60
or higher.

Preheat the engine

1. Check whether the pressure

building line is properly opened

The pressure building line isn't opened, and

the pressure building is unavailable. Result
in the shortage of gas output

Confirm that the pressure building line is

opened

2. Regulate the pressure of the

pressure building regulator cylinder,
find that the pressure doesn't increase
yet, it indicates that the regulator fails.

The pressure building regulator failure,

which can't build the pressure. Result in the
shortage of gas output

Regulate, replace the pressure building regulator

See the below in this document: Regulation of
the pressure building regulator

Page 3 of 7 pages

Underpowered

The cylinder pressure continuously

decreases;
The pressure building coil is frosted;
The buffer tank pressure is low;
(Poor pressure building)

3. Replace the pressure building

regulator, and find that the cylinder
doesn't build the pressure yet

The pressure building regulator is blocked.

LNG liquid can't flow in, and the pressure
can't be built. Result in the shortage of gas
output

Remove the pressure building line, and purge

and rinse it with the dry nitrogen

1. Increase the set value of the

pressure building regulator, and check
the variation of the cylinder pressure

The set value of the pressure building

regulator is low, and although the pressure
can be built but the pressure building effect
is bad

Adjust the set value of the pressure building

regulator
See the below in this document: Regulation of
the pressure building regulator

2. Increase the set value of the

economizer regulator. Check the
variation of the cylinder pressure

The set pressure of the economizer regulator

is low and thus results in the reduction of the
cylinder pressure. Although the pressure can
be built, the pressure building effect is bad

Adjust the set value of the economizer regulator

See the below in this document: Regulation of
the pressure building regulator, Regulation of
the economizer regulator

Check the set value of the engine

stabilizer;
Increase the set value of the regulator;

The set value of the line regulator is lower

than the pressure of the engine stabilizer

Adjust the set value of the line regulator

See the below in this document: Regulation of
the economizer regulator

Adjust the line regulator, and check

the variation of the pressure gauge of
the buffer tank

The line regulator failure results in the

unstable gas supply pressure

Adjust or replace the line regulator

See the below in this document: Regulation of
the economizer regulator

Adjust the pressure building regulator,

and check the variation of the cylinder
pressure and the pressure gauge of the
buffer tank

The unstable pressure building results in the

fluctuation of the cylinder pressure and the
unstable delivery

Regulate or replace the pressure building

regulator
See the below in this document: Regulation of
the pressure building regulator

Check whether the pipeline and

connection are frosted and frozen

The pipeline leakage, results in the low

engine gas-supply pressure

Replace or tighten

Check the pressure gauge of the buffer

tank, and find that its value can't
almost increase after the pressure
decreases

The delivery check valve is quickly opened,

which results in the take-off of the excess
flow valve

Warm the excess flow valve with lukewarm

water; or wait for a period of time, the excess
flow valve is automatically opened

The cylinder pressure is normal and

steady;
Underpowered

The pressure building coil is frosted;

The pressure of the buffer tank is

Power unstable

Engine fails to start

up or suddenly halt

normal;
The cylinder pressure gauge is
stable;
The pressure gauge of the buffer
tank fluctuates;
The pressure building coil is frosted;
The cylinder pressure gauge
fluctuates;
The pressure gauge of the buffer
tank fluctuates;
The pressure building coil is frosted;
The cylinder pressure gauge is
normal;
The pressure building coil is frosted;
The pressure gauge of the buffer
tank fluctuates;
The cylinder pressure gauge is
normal;
The pressure building coil is frosted;
The pressure gauge of the buffer
tank reduces in reading;

Page 4 of 7 pages

The cylinder pressure

quickly
or
continuously rises

The safety valve

exhausts for a long
time

The cylinder pressure gauge is

normal;
The pressure building coil is frosted;
The pressure gauge of the buffer
tank is low in reading;

Check whether there is any leakage

point in the pipeline

The pipeline suddenly fails, which results in

the take-off of the excess flow valve, and
prevents the leakage of the LNG

Tighten the leakage point, and replace the

damaged part

The cylinder pressure is low;

The pressure building coil is frosted;
The pressure gauge of the buffer
tank is low in reading;

Check the pressure gauge of the buffer

tank, and find that its pressure reduces
and then slowly rises

The set value of the economizer regulator is

low and thus results in the reduction of the
cylinder pressure.

Adjust the set pressure of the economizer

regulator
See the below in this document: Regulation of
the economizer regulator

The cylinder pressure is normal;

The pressure building coil is frosted;
The pressure of the buffer tank is
normal;

Check the set values of the regulator

and then engine stabilizer

The pressure of the rear-end of the regulator

is lower than the engine stabilizer pressure
requirement

Adjust the set pressure values of the regulator

and then engine stabilizer

The cylinder surface is normal, its

pressure exceeds the set value of the
safety valve, without exhaust

Check the safety valve by using the

vibration method;
The exhaust failure exists still, and
checks the pressure gauge of the
cylinder.

The safety valve is seized or fails

Calibrate or replace the safety valve;

Calibrate or replace the pressure gauge;

The cylinder surface is normal, its

pressure quickly rises, without
exhaust

Check the frosting of the economizer

regulator circuit; the frosting is
abnormal, and the set value of the
economizer regulator is wrong

The economizer regulator is overhigh in set

value or fails, the cylinder pressure can't be
released according to the specified value

Adjust the set pressure value of the economizer

regulator or replace it

The cylinder surface is normal, its

pressure quickly rises, without
exhaust

Check and find that the economizer

regulator circuit is normal, and the
delivery check valve fails

The delivery check valve fails and can't be

closed. The gas fills back and thus result in
the increase of pressure

Replace the delivery check valve

1. Check whether the

building coil is frosted

The pressure building coil is opened for a

long time, and the pressure quickly rises

Close the pressure building regulator

The safety valve isn't closed after opening

Calibrate or replace the safety valve

pressure

The cylinder surface is normal, and

the pressure is normal
2. Check it by using the vibration
method,and find that it still exhausts

Page 5 of 7 pages

3. The set value of the safety valve is

low or fails

The safety valve isn't closed after opening

Calibrate or replace the safety valve

The safety valve

slowly exhausts for a
long time

The cylinder surface is normal, and

the pressure is normal

Check it with a screwdriver with a

wooden handle by using the vibration
method

The safety valve is frozen

Normal

The safety valve

exhausts for a long
time

The cylinder pressure continuously

rises, its surface is condensed or
frosted, and the safety valve
continuously exhausts until drains
out

Check the condensation and frosting

of the cylinder surface, and check the
variation of the pressure gauge of the
cylinder

The vacuum of the cylinder reduces or fails,

and the thermal insulation property
decreases

The cylinder is subjected again

vacuuming treatment or replaced

Page 6 of 7 pages

to

the

Note three pressure parameters of the LNG system:

The set pressure value of the pressure building regulator: 0.9MPa;
The set pressure value of the economizer regulator: 0.8MPa;
The set value of the line regulator, i.e., pressure stabilizer: 0.86MPa.
Since the failures of the pressure gauge, liquid fuel level display and transmitter are simply, visually
diagnosed, they arent described in details.

Page 7 of 7 pages