TVSBusinessCase

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TM

OPW Fueling Components EMEA


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Executive Summary The scope of this document is to explain the operation and benefits of OPW Total Vapour Solution , aswell as installation and maintenance requirements. In addition, this document also defines the processof ordering: starting from inquiry, through technical assessment of the chosen petrol station to theinstallation and starting up of the OPW TVS.

About OPW TVSThe OPW Total Vapour Solution (OPW TVS) is designed to maintain the vapour pressure in theunderground storage tanks at specific pre-determined pressure settings, as well as to process gasolinevapours back into liquid, returning it to the underground tanks (UST) as resalable fuel. OPW TVS isdesigned to be installed on petrol stations with Stage 2, or with some upgrades on sites with Stage 1alone.

How it worksOPW TVS is comprised of 4 elements: OPW Vaporsaver (converting vapours back into gasoline),Soft fill (reducing vapours during fuel truck delivery), Accumulus valve (returning vapour to liquidflow during delivery through vacuum) and Vapour Management Panel (prevents vapour from goingback to the tanker). After keeping more vapour in the ullage space, and reducing the creation of vapourduring delivery, vaporsaver turns on at a specific pressure level reached in the tank (+0.37 mBar) andstarts processing the vapours (air and hydrocarbon mixture) with membrane technology, by separatinghydrocarbon from air and cooling it to the liquid state creating petrol and super saturated vapour thatgoes back into the tank. It automatically stops processing at (-2.5 mBar) reached in the tank. The air freedfrom the vapours is vented through PV vents.

Benefitsa | CommercialAll petrol stations lose certain amount of gasoline through evaporation, even with Stage 2 installed.Depending on several factors, these losses amount to between 0.25% and 0.45% of sales volume.OPW TVS reduces these losses to between 0.03% and 0.07%. If you calculate the difference (use forexample 0.3%), times the volume of gasoline sales, times the rising price of oil you will see that lossesare very large, especially at larger stations. OPW TVS can reduce these losses and save your money thatis currently evaporating, as number of already working sites have proven.

b | EnvironmentalDuring natural venting and especially dur ing fuel deliveries, pressure generated in the tanks is reducedby venting out through Pressure Vacuum (PV) valve a dangerous carcinogenic mixture of hydrocarbonsand air. This mixture pollutes the environment, and is especially dangerous in urban settlements.OPW TVS processes this mixture so that only clean air can be vented out through PV valve. This iscontrolled through a hydrocarbon sensor on the vent line. In the event of some hydrocarbons are passingthrough to atmosphere an alarm is sounded and the equipment checked so the environment is wellprotected.

Installation RequirementsOPW TVS performance is best utilized on stations with Stage 2 vapour recovery installed. With certainupgrades TVS can be also fitted on petrol stations with Stage 1. The technology can be customized to thepetrol station, but some of the benefits for easier installation would be that vent lines are connected in amanifold above ground (or manifold is easily accessible), there is a 3-phase electricity available and thereis physical space next to the f ill lines on the station for the location of Vapor Management Panel.

Maintenance and SupportOPW TVShas an expected life of 15 years, while key components on the vaporsaver unit also have a longlife (compressor 10 years; membrane 9 years). Certain standard maintenance of the vaporsaver (onceper year) is needed for checkups of wearable components (belts, gaskets, sealing). Vapor ManagementPanel, Soft Fill and Accumulus valve are mechanical solutions with no maintenance needed. OPW Fueling

Components EMEA (Europe, Middle East and Africa) has an extensive network of distributors in over 75countries that will support the servicing, maintenance, warranty and any other customer defined issuerelated to OPW TVS. In addition, OPW keeps close contacts to its end-users and is always available forany assistance with regard to TVS.

OPW TVS Certifications and Listings:ATEX Listing SIRA 03ATEX 9535

TUV Certification 97-11.1

CARB Certification G-70-204A

CA State Fire Marshal GVRC 005:008:062

KHK Japan Approval File # 16-4-5

Mexico Approval Cert. #: SEGEMDGPCCAT-MTSRVDOVER/001/2004

ContactsName Position Email Telephone

Arthur L. Boroff Director of Vapor Recovery Sales

OPW Fueling [email protected] (1) 513 407 0025

Carman KobzaManaging DirectorOPW Fueling Components EMEA

[email protected] (49) 172 545 56 79

Bora FilipovicMarketing and Business Development ManagerOPW Fueling Components EMEA

[email protected] (420) 602 702 190

OPW Total Vapour Solution Business Case OPW Fueling Components 2009


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ContentsExecutive summary ...................................................................................................................................................2

Business Cases .............................................................................................................................................................5

Stage 1 and Stage 2 on Petrol Stations .........................................................................................................7

OPW Total Vapour Solution ..................................................................................................................................8

Softfill................................................................................................................................................................................9

Accumulus valve ......................................................................................................................................................10

Vapor Management Panel ..................................................................................................................................11

OPW Vaporsaver .......................................................................................................................................................12

Case Studies ...............................................................................................................................................................14

Electricity, installation and maintenance approximation ...............................................................16

Simplified order procedure ...............................................................................................................................19

List of appendixes

Appendix A (OPW Vapor Saver Installation Manual)

Appendix B (Site Survey)

Appendix C (I nstallation Check Sheet)

Example AShows petrol station with sales of 3 millionliters of gasoline per year and price of gasolineat 1.1 EUR

Petrol Station EXAMPLE A

Gasoline sales per year in litres 3 000 000

Number of gasoline tanks 3

Price of gasoline 1,10

Average losses due to evaporiza-

tion0,35%

Annual losses in litres 1 0 50 0

L os se s a ft er T VS i ns ta ll ed 0 ,0 5%

Annual losses in l it res after TVS 1 500

Saved gasoline in litres 9 00 0

Saved gasoline in euros 9 900

Maintanance annually includingamortized cost of membrane andcompressor replacement after 9and 10 years respectively

1 000

R un ni ng co st ( el ec tr ic it y) 3 56

Installation cost 8 000

Cost of TVS 50 000

Return on Investment (ROI) inyears

5,86

Lifet ime sav ings (15 years) 148 500

Lifetime cost 78 340

Lifetime profit 70 160

Example BShows petrol station with sales of 5 millionliters of gasoline per year and price of gasolineat 1.1 EUR

Petrol Station EXAMPLE B





tion0,35%

Annual losses in litres 1 7 500

Lo ss es a ft er T VS i ns ta ll ed 0 ,0 5%


Saved ga soline in litres 1 5 000

S ave d g aso li ne in e ur os 1 6 5 00


1 000

R un ni ng co st ( el ec tr ici ty ) 3 56


Cost of TVS 50 000


3,52

Lifet ime sav ings (15 years) 247 500





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Example CShows petrol station with sales of 7 millionliters of gasoline per year and price of gasolineat 1.1 EUR

Petrol Station EXAMPLE C





tion0,35%

Annual losses in litres 24 500

Lo ss es a fte r T VS i nst al le d 0 ,0 5%


Saved gasoline in litres 21 000

S ave d g as ol in e i n e ur os 2 3 1 00


1 000

R un ni ng co st ( el ec tr ici ty ) 3 56


Cost of TVS 50 000


2,51

Lifetime savings (15 years) 346 500



Example DShows petrol station with sales of 5 millionliters of gasoline per year and price of gasolineat 1.5 EUR

Petrol Station EXAMPLE D





tion0,35%

Annua l losses in litres 17 500

Lo ss es a fte r T VS i ns ta ll ed 0 ,0 5%

Annual losses in l it res af ter TVS 2 500

Saved gasoline in litres 15 000

S av ed g as ol ine i n e ur os 2 2 5 00


1 000

R un ni ng c os t ( el ec tr ic it y) 3 56


Cost of TVS 50 000


2,58

Lifetime savings (15 years) 337 500



Stage I Vapor RecoveryThe purpose of Stage I Vapor Recovery Systems at gasoline dispensing facilities (GDFs) is to routegasoline vapors into the tanker truck without releasing them into the atmosphere. The Stage I system,consisting of sealed product fill and vapor apparatuses or both in one apparatus, is activated by aconnecting hose that allows the transfer of vapors from the underground or aboveground storage tank back to the tanker trucks empty tank compartment while the tanker truck unloads gasoline product(s)into the storage tank(s). All connections are tightly fitted and properly sealed to prevent the escape of vapors.Environmental Benefits: When using Stage I Vapor Recovery equipment, the escape of gasoline vapors isheld to a minimum, helping to limit the escape of pollutants that contribute to air pollution. In addition,they are able to save money in the long run by having the majority of gasoline vapors retained in thetanks. Some of the captured vapors are converted back into the liquid gasoline state while the restremains in the vapor state.

Stage II Vapor RecoveryStage II Vapor Recovery Systems collect gasoline vapors from vehicles fuel tanks while customersdispense gasoline products into their vehicles at gasoline dispensing facilities. The Stage II system consistsof special nozzles and coaxial hoses at each gasoline pump that captures vapors from the vehicles fueltank and routes them to the stations underground or aboveground storage tank(s) during the refuelingprocess.

Environmental Benefits: When using Stage II Vapor Recovery equipment, the escape of gasoline vaporsis held to a minimum, helping to protect the customers from the harmful effects of gasoline fumes aswell as minimizing the escape of pollutants that contribute to air pollution.

(Source: Illinois Environmental Protection Agency)

Petrol stations to install fume capture Systems(Press Release, European Commission, May 5th 2009)

The harmful petrol vapour which escapes during the refuelling of cars at ser vice stations will have to becaptured according to a deal reached with the Council, which has been confirmed today by the EuropeanParliament. Petrol vapour contains benzene, which is known to cause cancer, and contributes to theformation of groundlevel ozone (smog), one of the air pollutants most damaging to human health andthe environment.The European Parliament today confirmed a first-reading agreement reached in informal negotiationswith Council which demands that stage II petrol vapour recovery technologies will become compulsoryat new or renovated service stations with large throughput as of 1 January 2012. Almost all servicestations (small ones will be exempted) will be obliged to install these new technologies by 2018, 2 yearsearlier than proposed by the Commission. An exception exists also for service stations used exclusivelyin association with the construction and d elivery of new motor vehicles.

The Member States will draw drivers attention to the recovery systems by appropriate labeling of petrolpumps.



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OPW Total Vapour SolutionOPW TVS is the most effective way available today to prevent vapour venting into the atmosphere.On the forecourt, vapour is generated through tank pressurization and natural venting, during quiettraffic periods. Further vapour is produced during the delivery process as the tanker drops fuel into theunderground tank. Finally, on sites with Stage 2 systems, the vapour being recovered by the vacuumpumps from the vehicles is returned to the underground tank.

In a typical vapour recovery application, during the fill process, vapour would be recovered by the deliverytanker because of a vacuum created in the tanker as the liquid is being delivered. Often overlooked, it isimportant to understand that even when the delivery tanker is delivering diesel, the tanker is connectedto the vapour recovery system and therefore vapour is drawn from the sites tanks.

OPW Total Vapour Solution ( TVS): Controls the creation of vapour over the duration of the delivery and within the storage tank on

a continuous basis

Keeps the product in a liquid state during a product drop to prevent vapour creation where thelargest losses occur

Manages the vapour collected from nozzles on Stage 2 systems

Maintains storage tanks in negative pressure by automatically converting excess vapours back into saleable fuel, further preventing vapour loss

There are 4 main components of the Petroman Total Processing, each playing an integral part in the totalprocessing of the stages 1B and stage 2 vapour, as well as the natural venting of the product.

On the forecourt vapour is generated through natural venting during the quieter period, further vapouris produced during the delivery process by the effect of the liquid passing into the tank and on sites withStage 2 systems the vapour being recovered from the pumps is returned to the underground tank.

On a normal site this va pour would be recovered by the delivery tanker during the fill process by virtueof the vacuum created in the tanker as the liquid is delivered. It is not always understood that evenwhen the delivery tanker is delivering diesel the tanker is connected to the vapour recovery system andtherefore vapour is drawn from the sites tanks.

TVS is designed to maintain the vapour, produced by these various processes, underground in the sitestank farm and then to process the vapour back to liquid which is returned to the underground tanks(UST). The effect of this system is to reduce the wet stock losses normally associated with deliveries and

provide the vapour as a saleable product.There are 4 main components of the system, each playing an integral part in the total processing of Stages 1B and 2 vapour and vapour produced by natural venting, which are:

1. Softfill

2. Accumulus

3. Vapour Management Panel

4. Processing Unit - vaporsaver

Softfill System

The delivery process causes turbulence in the tanks through the liquid passing down the drop tubeand exiting through the orifice directly into the tank. In order to control the delivery of the liquid the firstcomponent used is the Softfill system.

This is basically a beam which is attached to the bottom of the drop tube and this allows the liquid tofeed along the base of the tank and is delivered through a large number of small holes (having a totalsurface area much greater than the normal 4 orifice). The effect of this is to calm the delivery and thusreduce the vapour generation caused by the delivery.

The secondary action of the Softfill is to introduce the vapour mixture being returned into the liquid flow

by the Accumulus valve, back into the product within the tank in a controlled manner to aid the vapourintroduction back into the liquid.

This is retrofitted through the existing 4 tee on top of the tank and can be easily removed formaintenance.



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Accumulus valve

During the delivery the vapour generation occurs within the spirit tanks and this passes from tank totank through the vapour recovery manifold.

The vapour air mixture that is generated is rich in hydrocarbons and the Accumulus valves works to reducethe pressure in the tank and to introduce the vapour back into the liquid flow, causing the hydrocarboncomponent of the mixture to be entrained back into the liquid.

The valve itself is positioned at the top of the drop tube, in the tank, in the vapour space. The valve formspart of the drop tube and is positioned below the overfill prevention valve.

The design of the valve utilises the liquid flow to create a vacuum, this is done by passing the liquidbeing delivered to the tank through a venturi which creates a vacuum at the centre. This area of vacuumis linked to the vapour space in the tank by a tube and this vacuum pulls the vapour air mixture beinggenerated back into the liquid flow from the tanker, thus entraining the hydrocarbons back into theliquid.

The effect of this is to reduce the generated pressure during the delivery.

Vapour Management Panel

On a normal delivery the delivery tanker would connect up to the vapour recovery point when offloadingdiesel and petrol. The effect of the tanker is to pull the vapour from the underground tanks, back into thetanker. Even when diesel is being offloaded, with the vapour recovery hose connected, the tanker pullsthe petrol vapour from the UST. The effect of this is a loss in vapour that can equate to 20 30 liters of fuel per delivery.

The vapour management panel is positioned on the vapour recovery manifold between the UST and thevapour recover hook up point. The panel contains two sets of valves, the primary valves are for vapourmanagement and these valves are inserted into the panel and control the vapour allowed from the USTto the tanker.

The valves are weighted to lift when the pressure in the UST reach 34 mbar, the effect of these valves isto prevent vapour from returning to the tanker when diesel is being offloaded. The valves will remain

closed during this process and the tanker will pull air into the tanker through its own vent system.Once the delivery of spirit is started the pressure will start to build up in the UST, but to a lesser extentthan on a normal site because of the above components, as the pressure increases this is held back bythe valves and the processing unit start to work (this is explained below).

The valves will not lift until a pressure of 34mbar is reached and with the other components operatingthis pressure may not be reached at all throughout the delivery process, thus meaning no return of vapour to the delivery tanker.

Once the tanker has finished its delivery, the valves close and trap the vapour in the UST, this vapour isthen processed back to liquid.

The secondary valves in the panel are the PV valves which are normally positioned at the top of the ventstack. These have been brought down to low level for ease of maintenance and weather caps put ontothe vent stacks.

The benefit of the vapour management panel is to reduce or eliminate the vapour going back to thetanker and to trap the vapour in the UST, so that it can be processed back to liquid.



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OPW Vaporsaver

As explained above the effect of the vapour management panel is to retain the vapour in the UST.In addition to this, vapour is returned to the tanks by the Stage 2 system on the pumps and also throughnatural venting during quieter times on the forecourt.

The OPW processing unit is provided to process the vapour back to liquid and thus a saleable product.

The OPW processor consists of a vacuum pump, compressor and membrane system and is an ATEXapproved system. The processor is linked into the vapour recovery manifold and a pressure switch builtinto the system monitors the pressure in the UST.

When the pressure increases to more than 2mbar, the processor automatically starts and the vapour/air mixture is passed through the membrane. The membrane allows the hydrocarbon element to passthrough but prevents the air from exiting.

This effect allows the air to be split from the hydrocarbon; the air which is clean can then be passed outto atmosphere through a vent system. The hydrocarbon element is pumped back into the UST and thisliquid stream is run through an inner pipe contained within one of the existing vent lines. This allows theliquid to be returned directly to the tank.

The vaporsaver is controlled from through various pressure switches and timers to allow it to runonly when needed. The main bulk of the processing will be done during and after a delivery with theprocessor then being utilised at other times to process the Stage 2 vapour and natural venting as andwhen required.

Operation of vaporsaver in several simple steps:As pressure in the storage tank rises, the pressure sensor monitoring the tanks will start the System.

1. The feed pump draws the vapour/air (saturated vapour) mixture from the storage tank.

2. The vapour/air flow is pressurised.

3. Increasing pressure within the same volume causes the vapour stream temperature to rise.

4. The heated vapour stream passes through a cooler.

5. The cooler reduces the vapour stream to ambient temperature.

6. The cooling process causes liquid gasoline to condense.

7. The vapour/air mixture and liquid gasoline go to a separator.

8. The liquid gasoline is separated, removed from the vapour/air mixture, and stored for later

removal and return to the storage tank.9. The remaining vapour/air flow proceeds to the membrane.

10. The membrane material has two sides, a pressure (feed) side, and a vacuum (permeate) side.

11. As hydrocarbon molecules pass along the membrane pressure side, they are attracted and bondto the membrane material.

12. Air molecules are repelled by the membrane surface on the pressure side, and continue on untilreleased from the Control System as clean air (residue).

13. The pressure differential between the pressure side and the vacuum side cause the hydrocarbonmolecules to be drawn through the membrane material.

14. The vacuum pump returns the supersaturated gasoline vapour (permeate) to the storage tank where some of it will condense into liquid gasoline.

15. When the pressure in the storage tank is reduced a preset level, the Control System is shut downand put into stand-by mode waiting for the pressure to rise again.

16. The separator valve is then opened, and the stored gasoline liquid in the separator is released tothe UST.

The principle of the membrane separation is called selective permeability or molecular selectivity. Themembrane allows the hydrocarbon molecules to readily pass through while the air (oxygen and nitrogen)molecules are less permeable and are vented to the atmosphere.

The Overall Effect of OPW TVSThe overall effect is the storing of the vapour produced during a delivery, thus reducing the vapourbeing returned to the tanker, the processing of all stored and Stage 2 vapour and the conversion of thevapour back to liquid.

The benefits of the system are that it offers a financial payback because of the liquid recovered from thesystem which would normally be returned to the tanker with a higher vapour content.

Each of the components compliments each other in reducing the pressure, maintaining the vapour in theUST and processing this vapour back to liquid.



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Case Study 1

30th June 2008 to 30th June 2009

Period Gasoline Sales Loss/Gain in Liters Variance in %

30 th June to 3 0th September 20 08 3,68 0,957 -2,60 5 -0 .07%

1st October to 3 1st December 200 8 3,56 8,963 -616 -0 .02%

1st Januar y to 31st March 2009 2,967,833 -1,007 -0.03%

1st April to 30th June 2009 2,894,259 -5,246 -0.18%

Cumulative Figures 13,112,012 -9,474 -0.07%

Expected Industry Operat ing Losses 13,112,012 -39,336Based on a normal loss

of 0.30%

Expected Industry Operat ing Losses 13,112,012 -32,780Based on a normal loss

of 0.25%

Savings Created with Total Vapour Management over 12 month trial

Potential Annual Savings (Litres) 29,862Based on a normal loss

of 0.30%

Potential Annual Savings (Litres) 23,306Based on a normal loss

of 0.25%

Case Study 2

Two Sites - One with T. V. S one without

Glendhow SS Sales Losses % Loss Litrs Corrected %StationLosses

A.T.C % A.T.C Losses

August 296401 0,97 2874 0,60 1777,3 0,37 1096,68

September 303965 0,89 2702 0,66 1850,9 0,28 851,10

October 295490 0,56 1662 0,44 1425,6 0,08 236,39

November 113489 0,11 128 -0,10 366,33 -0,210 -238,33

December 82281 0,38 316,00 0,38 139,1 -0,215 -176,90

TOTALS 1009345 0,73 7366 0,55 5559,25 0,18 1768,95

White Cross SS Sales Losses % Loss Litrs Corrected %StationLosses

A.T.C % A.T.C Losses

August 330209 0,69 2285 0,32 1063,23 0,37 1221,77

September 332852 0,47 1574 0,25 642,01 0,28 931,99

October 356844 0,32 1149 0,24 863,52 0,08 285,48

November 338301 -0,21 -725 0,02 70,01 -0,235 -795,01

December 72144 -1,03 -745 -0,80 -575,46 -0,235 -169,54

Totals 1430350 0,25 3538 0,14 2063,32 0 ,10 1474,69

Gledhow S S Period 1st Aug - 7th DecSales Stock Loss Loss/Delivery

1009345 5281.05 125.57

Deliveries 24000

White Cross S S Period 1st Aug - 7th DecSales Stock Loss Loss/Delivery

1453426 2071.30 34.20

Deliveries 24000

Savings 72.76%



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Electricity, maintenance and installation costs

User Interface Power Consumption User Interface (240 Volts @.5 Amps)

Kilawatt hours/year 1059 kWh

U.S. Based cost per year @ .04 USD/kWh (Peak)

Example User interface Power Cost/year $ 42.36

3 Phase Control System Power ConsumptionHP Rating 2.4 HP

Power Consumption ( 1 unit installed ) 1.8 KW

Power Consumption ( 2 units installed ) 3.6 KW

Avg. Run Time Per Day (1 unit installed ) 240 Min

Avg. Run Time Total per Day (2 units installed ) 480 Min

Kilowatt Hours/Year (1 unit installed ) 2630 kWh

Kilowatt Hours/Year (2 units installed ) 5260 kWh

U.S. Based Cost per Year @.04 USD/kWh (Peak)

Example 1 1 Unit Installed

Control System Power Cost/year $ 105.20

Example 2 2 Units Installed

Control System Power Cost/year $ 210.40

Total Annual Power Cost (1 system installed) $ 147.56

Total Annual Power Cost (2 systems installed) $ 252.76

Installation Labor Cost Projection

Man-Hours Cost @ $60/hr

6 Control System Installation $ 360.00

2 User Interface Installation $ 120.00

8 Total $ 480.00

Piping and Wiring Excavation Required (pre-existing Site)32 Piping Costs $ 1,920.00

16 Wiring Costs $ 960.00

4 Startup and Testing $ 240.00

52 Total $ 3,120.00

Total Installation Cost for Pre-Existing Site (Excavation Required) $ 3,600.00

Piping and Wiring No Excavation Required (New Site)16 Piping Costs $ 960.00

8 Wiring Costs $ 480.00

4 Startup and Testing $ 240.00

28 Total $ 1,680.00

Total Installation Cost for Existing Site (No Excavation Required) $ 2,160.00



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S mplifiedProcedure

ForInstallingPW TVS

tour

PetrolS ation

Maintenance Labor Cost Projection

List Price Component Man Hours Cost @ $60/hr

$ 3,250.00 Compressor 1 $ 60.00

$ 5,825.00 Vac Pump 2 $ 120.00

$ 9,000.00 Membrane 1 $ 60.00

$ 45.00 Vac Belt 1 $ 60.00

$ 45.00 Compressor Belt 1 $ 60.00

$ 18,165.00 Totals 6 $ 360.00

$ 1,211 Adjusted cost per Year Based on Third Party Requirements for Replacement Interval

NOTE: Replacement based on an expected life of 9.5 years of the membrane, vacuum pump and compressor.

Vaporsaver expected life is 15 years, so maintenance cost is put in relation with that number of years.

Component parts price shown is LIST PRICE. Actual price will vary.

Actual cash outflow will only follow once the components need replacing, so for the first 9 years there is no

expected cash outflow, apart from possible vac and compressor belt replacement.

Simplified

ProcedureForInstallingOPW TVS

AtYour

PetrolStation


User inquires with OPW or withdistributor about OPW TVS

OPW instructs user on choosinga proper site for TVS

OPW instructs user to fill in the sitesurvey form and provides photos

of the site or layout

Following approval of the site,OPW tests the site for vappour

tightness

Following acceptance of the user,parties agree on date

of installation

User sends in official purchaseorder, with OPW returning

acknowledgement withagreed terms

Following successful installation,OPW stays in contact with user

to track performanceand regular service

After site passes the test, OPWprovides a drawing proposaland installation procedure,

together with commercial offer


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TVSBusinessCase