ENG

STRALIS

L N G s y s te m - Re q u i re m e n t s fo r L N G re f i l l i n g s t a t i o n
This document gives general information on the requirements of the LNG system for the
refuelling of the Stralis NP 400 and 460. Always carefully read the user manual before any
operation of the vehicle.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

To prevent any unintentional contact of the
cold liquid, cold appliances or gas with skin
or eyes which could cause freezing and burns,
the operator in charge of refuelling must wear
suitable clothing including:
• Cryogenic protective gloves
• Long-sleeved, close fitting shirts and clothes
• Long trousers or overalls
• Work shoes
To protect the eyes and face, the operator must
wear:
• protective goggles and a visor above

MINIMUM REQUIRED FUEL SPECIFICATION

The composition of the natural gas must have the minimum following
characteristics:
• CH4 > 83% v/v methane
• NMHC < 13% v/v nonmethane hydrocarbons
• CO2 < 14% v/v carbon dioxide
• N2 < 14% v/v nitrogen
• H2 < 5% v/v hydrogen
• H2O < 55 mg/Nm3 water
• MN > 70 Methane Number, according to the AVL
method of Kubesh, King and Liss
• H2S < 10 ppm - total Sulphur < 10 mg/Nm3, according to ISO 6326-5
• contaminants according to ISO TR 15403
• siloxanes < 5 mg/Nm3
NOTE:
• % v/v indicates the percentage by volume of the substance into the total
volume of the fuel.
• Nm3 indicates the volume calculated under standard conditions: 293,2 K and 1 bar.

FUEL FILTRATION
Since LNG, like any liquid fuel, can pick up and transport debris that can cause
fuel system problems a 250 micron or finer fuel filter is mandatory on all fuel
station fill lines.

VEHICLE WORKING PRESSURE

All the values in bar shall be considered as bar gauge where barg indicates the
pressure, in unit of bars, above atmospheric pressure.
For optimal operating conditions, the stabilized pressure of any LNG tank after
the refilling shall be equal or higher than the standard working pressure of the
LNG tank.
In the table below the description of the characteristics of pressure for the
LNG tanks and the meaning of the colour codes of the sticker on the LNG tank
pressure gauge:

A C

Optimal Maximum
Severe Standard pressure pressure
engine working during (primary
derating Minimum standard safety valve
Version pressure
pressure operation set pressure)
(economizer
set point)
A B C
Stralis NP 400
7 bar 8,5 bar 7,5 ÷ 9.5 bar
(Cursor 9 engine)
≤6,5 bar 16 bar
Stralis NP 460
8 bar 9,5 bar 8,5 ÷ 10.5 bar
(Cursor 13 engine)

• Pressure ≤ 6,5 bar: insufficient injection pressure. Risk of power reduction and
risk of permanent damage to the catalyst.
• Pressure between 6,5 and 7,5 bar (Stralis NP 400 - Cursor 9 engine): no risk of
damage for the catalyst, but not favourable as power reduction may occur.
• Pressure between 6,5 and 8,5 bar (Stralis NP 460 - Cursor 13 engine): no risk of
damages for the catalyst, but not favourable as power reduction may occur.
• Pressure between 7,5 and 9,5 bar: optimal pressure interval for Stralis NP 400
(Cursor 9 engine).
• Pressure between 8,5 and 10,5 bar: optimal pressure interval for Stralis NP 460
(Cursor 13 engine).
• Pressure between 10,5 and 16 bar: not critical for vehicle use, but reduced hold
time for venting.
• In case the inner pressure is > 16 bar than the primary safety valve may be not
working properly. Contact the Service Network.

If, after refuelling with LNG, the stabilized (5 minutes after completing the
refuelling) inner pressure of the tank is lower than the minimum value in the
table, an incorrect refilling has been carried out by the LNG station manager/
operator. The vehicle shall not be used /operated until tank pressure has raised
to the minimum value. As a general guideline, the inner pressure of the LNG
tank raises 1 bar per day in standard conditions.
FUEL DELIVERY CONDITIONS
The LNG refilling station should be pressurized to at least 3 bar above the
vehicle working pressure.
The LNG tanks mounted of the Stralis NP are equipped with a primary relief
valve set at 16 bar in order to avoid overpressure. The delivery pressure of the
LNG station shall not exceed 15 bar.
In case of refilling procedure with “VENT” valve connected, the LNG station
should be designed to reduce the fuel tank’s pressure at least 1 bar below the
vehicle working pressure.
The station shall refill only saturated LNG.
The following table shows the saturation temperature and pressure for LNG.
In case the LNG station has a temperature and/or pressure gauge verify that
the station is refilling saturated LNG.
Temperature [°C] Pressure [bar] Temperature [°C] Pressure [bar]
-161.6 0 -116.3 13
-152.5 1 -114.6 14
-146.4 2 -113.0 15
-141.7 3 -111.5 16
-137.8 4 -110.0 17
-134.4 5 -108.6 18
-131.4 6 -107.3 19
-128.7 7 -106.0 20
-126.3 8 -104.7 21
-124.0 9 -103.5 22
-121.9 10 -102.3 23
-119.9 11 -101.2 24
-118.1 12

In the table below the maximum flow rate recommended for the refilling
of Stralis NP independently on the size of the LNG tank.
Version Recommended flow rate Maximum flow rate
Stralis NP 400 (C9)
50÷150 liter / min 200 liter / min
Stralis NP 460 (C13)

COMPATIBLE DISPENSER NOZZLES

Stralis NP LNG tank is equipped with Parker Kodiak receptacle that is
compatible with the 3 LNG station dispenser nozzles below:
• Parker Kodiac
• JC Carter
• Macrotechnologies
Parker Kodiak JC Carter Macrotechnologies
MAXIMUM LNG QUANTITY ALLOWED DURING REFILLING
The LNG tank of the Stralis NP is not equipped with any active system to
prevent the tank being overfilled.
The active system to avoid overfilling is responsibility of the LNG refilling
station.
In case of a vehicle with 2 LNG tanks, the master tank on the right side will fill
first, the filling pressure will increase and the slave tank will then fill completely.
The station’s active system to cut-off the flow of LNG shall not be too sensitive
to the LNG tank backpressure during refilling otherwise the slave will never be
filled completely.

IVECO recommends this active system that shall cut-off the flow of LNG from
the dispenser to the vehicle to be based at least on a combination of flow rate
and backpressure.
The LNG tank, according to its type shall not carry in any operational condition,
more fuel than is shown in the table below.
For vehicles with 2 LNG tanks, the maximum quantity of the LNG is the sum of
the net capacity of the 2 single LNG tanks.
Do not refill more LNG!

EXPLANATION: when the tank becomes full the pressure rapidly spikes up
to the station’s delivery pressure and the flow rate falls off dramatically. The
reason the flow doesn’t immediately go to zero is because of the ullage tank.
The ullage tank has a small opening (relative to the main fill line). Once the
main tank goes full there will still be a small flow into the ullage tank. When the
rapid pressure rise or flow drop is observed the tank is full and the station fill
valve should be shut. Even though it is still possible to put more liquid into the
tank by continuing to fill the ullage tank, the ullage tank is there to allow for fuel
expansion and standby time. If the ullage tank is completely filled the hold time
will be zero and the primary relief valve will open almost immediately after the
fill.

Refer only to the instrument cluster gauge to check the fuel level. The pressure
inside the tank gives no indication of the amount of fuel in the tanks.
Net capacity 4x2
Net capacity 4x2 6x2C
LNG tank model Section Gross capacity (maximum kg low rigids
(litre) artics artics
of natural gas) artics

HLNG-158 598 litre 540 litre 195 • - - •

HLNG-119 26’’ 450 litre 410 litre 150 • - - •
HLNG-73 276 litre 250 litre 90 • - • •
HLNG-114 24’’ 431 litre 400 litre 140 - • - -

The model (e.g. HLNG-158) can be found on the type approval plate welded on
the LNG tank.
The table shows the LNG tank models that can be mounted on each vehicle
configuration.
LNG TANK MAIN COMPONENTS LOCATION
1) Vapour manual shut-
off valve (close during
3 4 standard operation)
2) Liquid manual shut-off
valve (open at all times
unless emergency or
maintenance and repair
of the LNG system)
3) Vent connection for
5 the dispenser
1
4) Pressure gauge
5) Filling line receptacle
2

LNG TANK FUNCTIONAL SCHEME

SECONDARY SAFETY PRIMARY SAFETY
VALVE (24 bar) VALVE (16 bar,
with RED CAP connected to the vent
VAPOUR MANUAL SHUT-OFF stack behind the cab)
VALVE (GREY, closed in
standard operation) NON RETURN
VALVE
LNG
PRESSURE GUAGE
RECEPTACLE
(gives no indication
PARKER KODIAC
ECONOMIZER of fuel level)

ULLAGE TANK
LIQUID MANUAL (Never refill to more
SHUT-OFF than the net capacity)
VALVE
(RED, open in
standard
operation)
EXCESS
FLOW
VALVE
HEAT EXCHANGER PRESSURE CLUSTER FUEL
REGULATOR LEVEL LEVER
GUAGE SENDER

ACTIONS REQUIRED BEFORE DRIVING AND REFUELLING

Before starting to drive or refuel, check that the
red plug is present on the secondary safety valve
and is fitted correctly (on both tanks if the vehicle
is equipped with 2 LNG tanks).
A missing plug indicates a potential issue with the
primary safety valve.
In this case immediately contact your nearest
Network Service workshop.
 The protective door of the receptacle must be
closed to start the engine.
Check that the retaining lever is correctly hooked
to the protective door and locked by the safety
1 mechanism (1).
In the event of the protective door opening
whilst vehicle is in motion, the engine will stop
when the vehicle slows down to 3 km/h.
There is no error indication if the protective door
is open.

STANDARD FILLING PROCEDURE ( PRESSURE < 10 bar )

Before starting the refuelling procedure, check with the manager / operator of
the filling station whether the refuelling procedure shall be different from what
is shown below.

01. Connect the clamp of the station ground cable

(when present) to a metal part of the tank.
Use the ground connection point of the LNG
tank to ensure a safe connection.

02. Open the protective door for the receptacle.

Remove the plug of the filling receptacle.

03. Clean the filling receptacle of the tank and the

dispenser nozzle with a compressed air gun.

04. Insert the LNG dispenser into the filling

receptacle.
05. Start refuelling. If/when the tanks are full,
the dispenser will stop automatically.
06. Disconnect the LNG dispenser nozzle.
07. Fit the plug back into the filling receptacle.
08. Disconnect the ground cable.
09. Close the protective door of the receptacle.
REFUELLING PROCEDURE WITH “VENT” VALVE CONNECTED
( PRESSURE >10 bar )
Before starting the refuelling, check with the manager/operator of the filling
station, if, based on the filling system and tank inner pressure, the VENT line
connection is recommended. Otherwise the reference value of 10 bar may be
used as the criteria for VENT line connection.
01. Connect the clamp of the station ground cable
(when present) to a metal part of the tank.
Use the ground connection point of the LNG
tank to ensure a safe connection.

02. Open the protective door for the filling

receptacle.
. Remove the plug of the filling receptacle.
. Remove the plug of the “vent” line valve.

03. With the compressed air gun, clean the filling

receptacle of the tank, the dispenser nozzle,
the station ventilation duct and the “vent”
connection.

04. Insert the LNG dispenser into the filling

receptacle.
Connect the station ventilation line to the
“vent” valve.

open 05. Open the vapour shut-off valve (grey valve).

Do not operate the fuel shut-off valve (red
valve)! It needs to remain open.
06. Close the grey valve when the pressure drops
below 9 bar.
07. Disconnect the station ventilation line from
the “vent” valve.
08. Fit the plug of the “vent” valve. Do not fill
LNG in parallel to the venting process.
09. Start refuelling.
10. Disconnect the dispenser nozzle.
11. Fit the plug of the filling receptacle.
close after 12. Disconnect the ground cable.
venting 13. Close the protective door of the receptacle.
14. Look to the instrument cluster gauge to check
if the tanks are full.
FIRST FILL OR HOT TANK FILLING PROCEDURE
01. Fill the tank as described in the “STANDARD FILLING PROCEDURE” till
point 04.
02. Start refuelling and put 8-16 kg of LNG into the tank.
03. Check that there are no visible leaks in the LNG system.
04. Drive the vehicle for 10-15 min to reduce the pressure inside the LNG tanks
and as a check for the fuel system. Pressure in both tanks will reduce below
10 bar.
05. Check again that the LNG system shows no sign of visible leaks.
06. Refuel as described in the “STANDARD FILLING PROCEDURE”
I V E C O S.P.A . – T E C H N I C AL INF O R M AT IO N & S E RV IC E E NG INE E R ING
L U N G O S T U R A L A Z IO, 1 5 / 1 9 – 1 0 1 5 6 TO R INO ( TO ) – ITALY
P R I N T E D : 6 9 2 6 9 2 6 3 – 1 S T E D. 0 3 / 2 0 1 9
© 2 0 1 9 . I V E C O S . P. A . A l l r i g h t s re s e r ve d .
P r i n te d i n It a ly
w w w. i ve c o. c o m
10
bar
START

close after
open pressure reduction