Precautions while using CNG

1. Compressed natural gas CNG Methane stored at high pressure can be used in place of gasoline petrol, Diesel fuel and propane LPG. CNG combustion produces fewer undesirable gases than the fuels mentioned above. It is safer than other fuels in the event of a spill, because natural gas is lighter than air and disperses quickly when released. CNG may be found above oil deposits, or may be collected from landfills or wastewater treatment plants where i .....

Naturally Safe

2. It comes as a surprise to many to hear that natural gas is one of the safest transport fuels available. Natural gas is a naturally occurring product, consisting mainly of methane approx. 90Percent. In its natural state, natural gas is odourless. As a safety measure, the gas is odorised prior to distribution to provide a ready means of leak detection. An average person can easily detect the smell of gas at a concentration as low as 0.3Percent by v .....

Pressure Safety

3. As CNG is stored at high pressure, it is often perceived that the high pressure of the product makes it more hazardous than other fuels. While a high pressure gas leak tends to make a lot of noise while the gas is escaping, the high pressure forces the gas to escape very rapidly causing high concentrations of gas to build up in the immediate vicinity of the leak. The resulting high concentrations of gas and its tendency to dissipate upwards make .....

Experts say CNGs safe

4. Automobile experts have ruled out the possibility of CNG causing fire in the Maruti Esteem car that collided with an auto on DND flyway on Thursday night. On the contrary, they feel that the fire could have been more devastating had the car been running on petrol. .....

Monitoring

5. As for all automotive vehicles, NGVs require regular maintenance to limit preventable accidents. For CNG powered NGVs regular inspection of the high pressure fuel storage vessels and fuel system components is best supported by a system that monitors compliance to national or regional regulations. .....

Safe Distribution

6. Natural gas has been distributed safely for years. In most circumstances, it is delivered via underground pipeline networks, the same networks that deliver natural gas to our homes and businesses. This method not only eliminates the need for road tankers to deliver fuel from the refinery, but also the need for ocean going oil tankers to deliver crude oil to the refinery. Hazards associated with each of these delivery methods are unfortunately wel .....

Warning Statements Used in this Manual

7. All replacement parts must adhere to the accepted standards and ratings as specified by Agility Fuel Systems. The usage of any part that is not approved by Agility Fuel Systems is not recommended and may compromise the integrity and safety of the system.Do not remove components from original packaging until absolutely necessary. Any components that are to be reinstalled must be thoroughly cleaned, inspected, and stored in a satisfactory manner un .....

WARNING

8. If the vehicle has been in an accident or fire, cylinders and system must be examined by a qualified inspector. .....

Qualified Personnel

9. CNG systems should be maintained and nspected exclusively by trained personnel. As with all pressure vessels, CNG storage and fuel delivery systems are dangerous. .....

Safety Equipment

10. 1. CNG safety signage should be visible at all applicable locations as stipulated by federal, state and municipal law. 2. Natural gas rated fire extinguishers should be accessible and visible throughout all servicing and fueling areas. Be sure that fire extinguishers are charged and up to date. 3. In case of emergency, self contained breathing apparatus should be on site in an easily accessible area. 4. Areas designated for CNG fueling systems mu .....

General Safety Precautions

11. 1. Follow all maintenance procedures in order; do not skip steps unless so noted. 2. Never use an open flame as a source of illumination in proximity to a CNG system. 3. Any process or procedure that generates sparks, flames or heated particles should not be practiced in areas designated for CNG. 4. If a CNG system requires a process or procedure that generates sparks, flames or significant heat, conduct the procedure in an isolated area and make .....

CNG Vehicle Safety Precautions

12. The following safety precautions should be considered at all times when operating natural gas fuel systems and equipment 1. A portable fire extinguisher must be installed on the vehicle in an easily accessible location. 2. Do not start the engine if a natural gas leak is detected. 3. Never attempt to open system components that are under pressure. 4. System pressure must not exceed 3000 psi for public vehicles in Canada. 5. For all other vehicle .....

Welding And Hot Work Precautions

13. For any welding in or near a CNG storage system, consider the following recommendations 1. Ensure the vehicle is in a well ventilated area. Do not park the vehicle in an area where natural gas may accumulate. 2. Turn all cylinder shutoff valves to the closed position. 3. Make sure the manual shutoff valve on the FMM is turned to the ON position.4. Turn on the vehicle and run the engine until it stops. 5. Ensure the vehicle is off and proper vehi .....

Repressurize After Welding

14. 1. Make sure vehicle is turned off and keys removed from the ignition. 2. Ensure bleed valve is closed. 3. Ensure low pressure coalescing filter is reconnected. 4. Perform a leak test and repair any leaks. 5. Reconnect the electrical connectors and main vehicle battery. 6. Re install the FMM cover. 7. Slowly turn the cylinder shutoff valves to the ON position. 8. Start the engine. .....

Codes and Compliances

15. For complete and detailed information concerning CNG codes and regulations please refer to the following. .....

Storage Cylinders

16. The storage cylinders for CNG fuel are housed in metal frames that are bolted to the truck body or chassis. These structures are designed to protect the cylinders in a collision. Each individual cylinder has a valve at one end which allows the fuel in that cylinder to be isolated from the rest of the fuel system. During regular operation, all cylinder valves are open, although some operators prefer to close one cylinder and use it as a reserve ta .....

Emergency Response for Gas Leaks

17. If the vehicle has sustained damage or a gas leak is detected 1. Do not approach the vehicle if any sources of ignition may exist such as fire, sparks, electrostatic charges, lights or electronic devices. a. If ignition sources may be present, vehicle fuel cabinet doors should remain closed. b. I if no ignition sources are present, keep the vehicle and fuel cabinet doors open to prevent gas accumulation. 2. If the vehicle is indoors, move the ve .....

Emergency Shut Down Procedure

18. To shut down a CNG storage system 1. Turn the ignition switch to OFF and set the parking brake. 2. Turn off the battery disconnect switch. 3. Shut off fuel at 1 4 turn valve on the FMM. 4. Inform emergency personnel. .....

Fuel System Components

19. All figures and illustrations are intended for reference only and do not necessarily reflect the exact configuration for any given system. All plumbing and fuel management module layouts are consistent across platforms; however there may be some differences depending on vehicle specific options. Please contact Agility Fuel Systems Product Support if you have any questions about your system that are not covered in this manual. .....

CNG Fuel Storage Cylinders

20. The composite containers cylinders on the vehicle are manufactured to comply with FMVSS 304, NAI IAS, or the CSA B51 Part 2 specifications. Containers must have permanent labels in accordance with applicable regulations. These labels provide valuable information to cylinder inspectors and service personnel. .....

High Pressure Filter

21. The high pressure filter is located in the FMM and is plumbed between the manifold and the solenoid valve. The high pressure filter purifies the fuel by removing moisture and contaminants. The high pressure filter element has an efficiency rating of 1 micron. It should be changed with every oil change or once every 3000 miles, whichever occurs first. When re assembling the HP filter, apply a silicone based spray lubricant on the filter bowl threa .....

Low Pressure Filter

22. The low pressure coalescing filters is usually located near the engine. The low pressure filter removes residual contaminants and oil from the fuel before it enters the engine. Consult the engine manufacturer for maintenance and replacement guidelines. .....

Depressurizing CNG Systems

23. 1. Ensure that the vehicle is turned off. 2. Turn all cylinder shutoff valves one on each cylinder clockwise to the OFF CLOSED position. 3. Ensure that the manual shut off valve is in the ON OPEN position. 4. Turn on the vehicle and run the engine until it stops. 5. Ensure that the vehicle is off and that the proper vehicle lock out procedures are followed. Remove the ignition key. 6. Check the gauges on the fill panel to ensure that all the pres .....

Testing and Finding Leaks

24. Fittings and connections should be checked periodically for leaks. This task must be carried out by qualified personnel. For monthly maintenance, the entire fuel system can be leak tested with leak detection solution, and or a methane detector. All joints and connections should be tested. Leaks usually occur at fitting connections. When checking for leaks always use certified leak detecting equipment and solutions designed for use with stainless .....

Leak Repair

25. Perform leak repairs in the order shown below. Note Move on to the next repair only if the previous repair did not fix the leak. .....

Replacing Filter Element

26. 1. Depressurize the system. 2. Drain the filter. 3. Unscrew the filter bowl by using a filter bowl removal tool or open end wrench. 4. Remove and replace the old filter element. 5. Inspect the O ring on the filter element holder for damage and replace if necessary. 6. Lubricate the filter bowl threads with a silicone lubricant. DO NOT allow lube to contaminate the bowl or filter element. 7. Reinstall the bowl and tighten to 40 ?1 ft lbs. .....

Returning to Supply

27. The third method returns fuel to a distribution system. When using this process, pressure in the vehicle cylinder and the supply system pressure will equalize, so some pressure may remain in the vehicle fuel system. .....

Compressor Transfer

28. In this defueling method, a compressor at the fueling station extracts the gas from vehicle. .....

Troubleshooting

29. The following section covers a variety of potential problems and their respective solutions. The issues addressed in this section are unique to CNG storage systems; however issues concerning other onboard systems may influence or directly cause problems with the CNG storage system. .....

Do not

30. Smoke or strike a match Operate any electrical switches or appliance controls, Pull an plugs from outlets Use a flashlight or lighter Use a telephone or cell phone from the building .....

A Safe Place to Vent

31. To vent the fuel that remains after the engine stalls or if the engine cannot be run to consume the fuel, the CNG can be vented safely into the atmosphere. Special precautions are necessary to safely vent the CNG without causing a fire. NFPA 52 Vehicular Gaseous Fuel Systems Code, the International Fire Code and some state and local regulations require that any venting system be approved by the Authority Having Jurisdiction AHJ, generally the fi .....

Verification That Each Cylinder Is Empty

32. If the cylinders are equipped with manual valves, these should be carefully cracked open after the piping is disconnected. If no significant pressure is present, the valve can then be fully opened, assuring that the cylinder is empty except for a small amount of gas at atmospheric pressure. .....

Safety measures

33. Always use approved CNG kit And cylinder. It is dangerous and illegal to use substandard cylinder and fittings. Do not install LPG, Propane or any other cylinder in place of a CNG cylinder. It is unsafe and unlawful. It is advisable to have insurance coverage of the CNG kit along with the vehicle accessories. Always, park the vehicle at least 6 meters away from sources of ignition fire. Always refer to the CNG kit suppliers manual for operating .....

Daily safety checks

34. Make sure that clamps are tight and cylinder fixed properly and safely. Confirm that cylinder valve is safe and valve wheel is in place. Ensure that gas tubing is intact and supported properly. Check for gas leakage from the kit by using soap solution. .....

In case of gas leakage from CNG kit

35. Check out of the vehicle. Do not start the vehicle. Push vehicles to a place out side the station in open Air. Stop all activities in the vicinity, which can provide source of ignition, e.g. smoking, use of mobile phone etc. Close down the cylinder valve master shut off valve in the CNG system to control the leakage. Call CNG kit retrofitter to repair the same. .....

In case of fire

36. Evacuate the vehicle and surrounding place. Take help of fire fighting experts. Extinguish the fire with water fire extinguishers. If feasible, close down the cylinder valve master shut off valve in the CNG system to control the gas leakage. .....

Statutory requirements

37. Endorsement of CNG or bi fuel mode in Registration Certificate. Annual checking of the CNG Kit and maintaining the certificate. Hydro testing of the cylinder, once in 5 years, as per Gas cylinder rules. Certificate of CNG Kit, Fitness and hydro test to be possessed by the driver all the time. Maintain cylinders in good condition. No repair to be done on cylinder and valves. No oil, Grease or lubricant to be used for cylinder. Dont change the colo .....

CNG Safety

38. CNG has the narrowest flammability range, leading to slim chances of catching fire in the event of a leakage. Simplified, it means that the combustible mixture of natural gas and air does not ignite if the mixture is leaner than 5Percent or richer than 15Percent of the air fuel ratio required for ignition. Thus, this limited inflammability range makes CNG one of the safest fuels in the world. Being lighter than air, in case of a leak, CNG just ri .....

Safety Aspects in CNG Refilling Stations

39. Ministry of Petroleum and Natural Gas may be asked to review the layout of the dispensing stations to ensure easy approachability to dispensers and protection of the installed pumps.Standardise all vehicle refuelling receptacles or nozzles on the NGV 1 standard to reduce filling time, minimise safety risk posed by leakage of gas due to O ring failure, and allow more efficient use of existing compression capacity. .....

Quality of Natural Gas

40. Ministry of Petroleum and Natural Gas may be asked to lay down the specifications of pipeline gas. The gas composition as indicated by methane content and the Wobbe index indicator to measure the effect of changes in gas composition on air fuel ratio and engine combustion should be laid down. .....

Certification process

41. The capabilities and capacities of the type approval institutions are inadequate leading to delays in testing. This should be improved in order to reduce the duration of the whole type approval procedure to reasonable, internationally common timeframes. The type approval procedure including the Information on Technical Specification to be Submitted by Manufacturer used by testing agencies needs to be reviewed in order to delete unnecessary. .....

Nozzles and safety

42. As of now, type approval certificate has been given to CNG vehicles fitted only with nozzles meeting New Zealand Standards NZS. These are prone to frequent o ring failures an item in nozzles. We are informed that they occur on an average about once every 20 fills. This failure not only interrupts fueling and requires replacement of the oring, it also creates a fire hazard due to the release of a significant amount of high pressure gas. .....

When Leakage is Detected

43. If, even after taking all the necessary precautions, a leakage is detected in a CNG car, there is no need to panic at all. All the owner driver needs to do is close the CNG cylinder valve to cut the gas supply, open all the doors, roll down all the windows and remember not to start the car in any condition. Later, a trained mechanic can be called to take a look at and repair the faulty system. .....

Check the Spark Plugs Regularly

44. To prevent any misfirings that tend to result from insufficient spark generated by the spark plugs, it is very important that the spark plugs are checked on a regular basis and replaced with new ones after every 13,000 15,000 kms.Also, the performance of a CNG car can be greatly improved if instead of continuing to use spark plugs meant for a petrol car, users opt for spark plugs specially designed for a CNG vehicle. .....

Gas leak smells like rotten eggs

45. If a really bad smell happens all of a sudden, get out of the house right away and find a grown up. .....

Dont hang on pipes

46. The pipes might come loose, letting the gas escape. And remind grown ups to keep the outside meter clear in case of an emergency. .....

Be very careful using a gas stove

47. Roll up your sleeves, keep towels and hot pads away from the flame, and make sure a grown up is around to help. .....

Savings

48. Total cost of ownership per unit of energy generated is less than many other competitive fuels. .....

Tank Inspection And Expiration

49. CNG fuel tanks must be US Dept. of Transportation DOT approved. As the structural integrity of CNG tanks degrade over time, all tanks are required to have an expiration label. Do not continue to use expired cylinders! CNG tanks and fuel systems must also be visually inspected after a motor vehicle accident or fire and at least every 36 months or 36,000 miles, whichever comes first, for damage and deterioration per DOT regulation FMVSS 304. CSA .....

Securing Tanks

50. CNG tanks must be secured to the vehicle body, bed, or frame to withstand a force of eight times the weight in all directions of a fully pressurized container 8x G force impact. Only accept the use of brackets and mounting designs which have been approved by the tank manufacturer. Never accept the use of ratchet straps, aluminum bands, etc. on your vehicle. .....

Shielding Tanks

51. Tanks must be protected from road hazards, loading, unloading, direct sunlight, exhaust heat, accidental cargo leakage. Shield must not directly contact tank nor trap solid materials or liquids. Cylinders And valves must be shielded with minimum 9 inches road clearance when tires are deflated and cannot be located ahead of the front axle or behind the rear bumper attachment. Must be transversely mounted if behind rear axle. .....

Fuel Lines

52. Corrosion resistant fuel lines generally stainless steel must be mounted, braced, and supported to minimize vibration and protected against damage, corrosion, or breakage due to strain or wear. No use of cast iron, plastic, galvanized pipe, aluminum or copper. Fueling connection must be ANSI listed. .....