January 2008

Prepared by

Booklet
On
Safe Practices / Check List in co-ordination with
for LPG Operated Vehicles
 Cell: +91-9343661660

RECOGNISED BY TYPE APPROVED BY SBI SBM

Govt. of India * Conditions apply

DSIR
TU/IV-RD/ 2523
ARAI
Progress through Research AUTO CLEAN
100%
Finance

AUTO GREEN
 Wa r m i
ng up to all the
action with more than 400
stations in the country now and
Auto LPG being available in more than
150 cities already, more and more vehicle
owners are converting to this Economical and
Environment Friendly Fuel, paving way for India to
become one of the largest Auto LPG markets in the world in
the next few years.

Low costs of infrastructure and conversion, easy availability,

versatility of use and of course, an impeccable safety record make
Auto LPG the only viable, un-adulterable and environment friendly
alternative auto fuel in India.

IAC, a member of Central Motor Vehicle Rules -

Technical Standing Committee (CMVR-TSC) &
Standing Committee on Emission Legislation
(SCOE), Government of India, is widely
recognized as the nodal body for the Auto LPG
Industry in India with practically all major
stakeholders on board. IAC membership base is
expanding rapidly and we now have the Oil
Sector PSUs, Private LPG Marketers, Kit
Suppliers, Equipment Manufacturers and
Turnkey Installers as members, in addition to a
very proactive support of World LPG Gas
Association, USAID, ARAI and SIAM.

We have been actively organizing Seminars,

Workshops and various activities for state RTO's
like that for Maharashtra, Karnataka, participating
at various International forums like World LPG
association activities in France, USA, China &
South Africa and initiating very meaningful
interactions with the leading OEs .

Please visit our comprehensive website at

www.iac.org.in for more details.
 IAC President, Mr. John Joseph and Vice President, Mr. Sunil Mathur
attended the WLPG's GAIN Council meeting in Nice, France in May 2007.
Mr. John addressed the gathering. The car in the photograph was driven
down to Nice from Paris, 800 kms away, all the way on ALPG, in 9 hours.

IAC Organized Seminar on Inspection & Safety in Aurangabad on July 28, 2007

IAC Delegation with General Motors India VP Mr. Ankush Arora

Fourth All Stakeholder meet at Mumbai in September 2006 IAC Delegation with Ford India President Mr. Arvind Matthew (4th from left) Shri S.K. Dash - Joint Secretary, Ministry of Road Transport & Highways,
Inaugurating the seminar by lighting a lamp

Shri S.K. Dash releasing IACs Inaugural Newsletter Shri P.C. Kataria (Jt. CCOE) addressing the delegates Shri P. Raghvendran - President - Reliance Ind Ltd.
(Refinery Business) delivering the key note address

Shri S.K. Hazra - Managing Director AEGIS Logistics Shri Balraj Bhanot - (Former Chairman CMVR Technical Committee) More than 75 Delegates participated in the Conference
Limited chairing the session on Infrastructure chairing the session on Retrofitments

Ms Anumita Roy Chowdhury with Mr S R Marathe (Director-ARAI) IAC Delegation at Auto Expo 2008 IAC Contingent at Mumbai Marathon 2008
and Mr M K Chaudhari (Sr Dy Director-ARAI)
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

Dear Users of Auto LPG:

AutoLPG (ALPG) is a fuel that has become very popular amongst the three and four
wheeler users in the country. The attraction to use ALPG is not only its cost savings but
also because it is a safe, clean, easily-available and environmentally friendly alternate
fuel.

Indian Auto LPG Coalition (IAC) had been formed to take the Auto LPG regime forward
in our country by observing international practices in the safe handling and usage of the
product. IAC was formed out of various stake holders such as Oil Cos., Retro-fitters,
LPG marketers/ importers, Govt. bodies such as Transport Depts., ARAI, and others.

This popular ALPG fuel is now available across the country in over 400 dispensing
stations and more and more stations are rapidly being put up by public sector oil
companies such as IOC, BPCL & HPCL and also private players like Reliance, Vanaz,
AEGIS, ELF, Gas Energy and so on. Simultaneously, Auto manufacturers (OEMs) are
working on adding more ALPG variants of vehicles. Also, leading authorized
retro-fitters are setting up conversion facilities in the various cities and towns of the
country.

As most of the cars today on the roads running on ALPG are retrofitted, it is most
important that ALPG consumers and also Transport Dept. officials know the various
aspects with regard to safe fitment and usage of this new alternate fuel in the vehicles.
This booklet, therefore, has been produced to serve as a ready reckoner, detailing all the
fitment and usage aspects connected with ALPG. I trust that you would find the same
useful.

If you have any suggestions, please feel free to log in to our website
http://www. iac.org.in and give the same.

Wishing you happy motoring with ALPG.

John Joseph
President (IAC)
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

TRANSPORT COMMISSIONER'S OFFICE

Administrative Building, 3rd & 4h Floor,
Near Dr. Ambedkar Udyan,
Government Colony, Bandra (East),
Mumbai 400 051
S. D. SHINDE, I.A.S. Tel. : 6516336
TRANSPORT COMMISSIONER

PREFACE

Today we live in modern Era of Civil Society where individual Rights particularly the
Right to Life are of immense importance. The present civilization is facing many
Problems as threatening of life of flora and fauna. The reason is pollution: particularly
vehicular pollution is one of them .The awareness about this problem and an action
regarding controlling pollution on global level started after the Earth Summit in 1992.
Search for alternate fuels which emit less amount of Green House Gases, was one of the
controllable measure adopted. In India and particularly Maharashtra, it started with
Hon`ble Mumbai High Court's Order under Writ Petition No. 1762/99.The High Court
gave order for phasing out old vehicles and conversion of vehicles to environment
friendly fuels like Compressed Natural Gas and Liquefied Petroleum Gas.

Maintaining a high safety standard during conversion to alternate green fuel is difficult
Task on the part of Auto Industries and Motor Vehicles Department, as it requires
adoption of new technology. While registering the LPG operated motor vehicle,
precautions are to be taken as the LPG is inflammable and is heavier than air.

The Transport Commissioner's Office has taken a leading step in 2001 by formulating
the guidelines for Retrofitment Centers and started conducting Training Programs for
the officers of the department and retrofitters.I appreciate the timely response given by
Indian Auto LPG Coalition for bringing out such informative handbook for field officers
working in Motor Vehicles Department in Maharashtra.

Ready Reckoner Booklet for Safe Practices is to be followed by Motor Vehicles

Department officers before registration of LPG operated vehicles. This publication is a
good endeavor by the Automotive Research Association of India which will help the
Registration authorities in applying checks while registering LPG operated vehicles
ensuring safety of the society as a whole.

At the end I express my gratitude to Shri John Joseph, President of Indian auto LPG
Coalition for bringing about this Booklet for the use of Motor Vehicles Department.

(S. D. SHINDE)
Transport Commissioner,
Maharashtra State, Mumbai.
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

FOREWORD
I am glad to understand that IAC is doing a commendable work by means of proactively
working with the transport authorities in promoting safety and inspection in the field of
auto LPG.
The training programmes for RTOs conducted in Bangalore and Mumbai is a good
beginning.
The booklet being published on auto LPG will be useful for everyone involved in the
field.
I wish all the best IAC in its noble endeavor to help the country to reduce pollution.
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

CONTENTS

SECTION 1 : USE OF LPG IN AUTOMOBILES

1.1.0 LPG General characteristics
1.2.0 Why Auto LPG
1.3.0 Why we should not use removable LPG cylinders in vehicles.
1.4.0 General instructions for motorists

SECTION - 2 : LPG CONVERSION KIT, ITS COMPONENTS AND FUNCTIONS

2.0.0 Auto LPG conversion kit

2.1.0 Auto LPG tank and accessories.
2.2.0 LPG delivery system
2.3.0 LPG control system

SECTION 3 : CHECK LIST FOR INSPECTION OF LPG VEHICLES BEFORE

REGISTRATION BY REGISTERING AUTHORITY

3.1.0 Details of vehicles

3.2.0 Details of LPG system
3.2.1 Tank installation
3.2.2 Multi function valve
3.2.3 Refilling valve
3.2.4 Fuel line safety check
3.2.5 Shut-off valve
3.2.6 Regulator
3.2.7 Gas-air mixer
3.2.8 Electrical wiring : safety checks
3.2.9 Automatic fill limiter
3.2.10 LPG filter
3.2.11 Compliance plate
3.2.12 Identification label in front and rear
3.2.13 Compartment / sub-compartment gas-tight housing.
3.2.14 Conduits / ducting
3.2.15 Petrol shut-off valve
3.2.16 Fuel selection
3.2.17 Low pressure hose
3.2.18 High pressure hose
3.2.19 Catalytic converter
3.2.20 ECU ( Lambda control with em ulator)

ANNEXURE
1. Form BTI
2. Form of Submission
3. Slip of endorsement in RC Book.
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

SECTION 1: USE OF LPG IN AUTOMOBILES

Pressure Reducer
Electric
Petrol Gas Switch
Solenoid Solenoid
Tank

Gauge
Line

1.1.0 LPG: GENERAL CHARACTERISTICS

1.1.1 LPG is termed as Liquified Petroleum Gas and is mixture of commercial

Propane and Butane . At ambient temperature and atmospheric pressure it is
a gaseous substance and can be condensed to liquid state by application of
moderate pressure. It is normally stored as liquid under pressure in spec ially
constructed tanks or cylinders. In the liquid state, it is a colourless watery
fluid.

1.1.2 Density Vapour LPG is 1.8 to 2 times heavier than air. In case of
leakages, it settles down at ground level and does not get easily dissipated in
air. In contrast, liquid LPG is lighter than water and floats on the surface of
water. Liquid density is approximately 0.54 to 0.56 at 15 deg. C.

1.1.3 Vapour Pressure The pressure inside the tank or cylinder is called the
vapour pressure at the observed temperature. As per BIS specification of
auto LPG, it may vary from 5.2 to 10.50 kg / sq. cm. at 40 deg.C. Hence the
tanks are specially designed under SMPV ( U ) Rules to withstand the internal
pressure.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

1.1.4 Flammability and Explosive Limit LPG has an explosive limit of 1.8% to
9.5% by volume in air. This means LPG will form an explosive mixture in this
range in air and will burn with explosion if ignited. Howev er, auto ignition
temperature of LPG is higher than that of petrol or diesel ( about 500 deg.C
compared to 325 C & 350 C respectively ) and hence it will not ignite on its
own at normal temperature.
1.1.5 Calorific Value- LPG has heating val ue of 10,900 Kcal / kg which is almost
comparable to Petrol.
1.1.6 Volatility Liquid LPG is highly volatile and expands about 250 times its
volume in air. Therefore leakage of LPG should be prevented before it
creates a great risk.
1.1.7 Cubical expansion Liquid LPG expands with temperature rise at a higher
proportion than petrol. This is why the LPG tanks should never be filled more
than 80% of its volume.
1.1.8 Odour - LPG does not have any smell of its own. But it is artificially
odourised for safety reasons by adding a small amount of ethyl mercaptan so
as to detect any leakage of escaping gas.
1.1.9 Colour LPG is colourless both in liquid and gaseous form . In case of
leakage, the vaporization of liquid cools the atmosphere and condenses
surrounding water vapour to form a whitish fog and make it possible to see an
escaping gas.
1.1.10 Viscosity- LPG has low viscosity of around 0.3 CS @45 deg C and can
leak when other petroleum products normally do not, thus demanding a very
high integrity in the pressurized system to avoid leakage.
1.1.11 LPG melts substances such as grease, oils and paints. It causes
swellings in natural rubber. This is why synthetic rubber is used for the hose
manufacturing.
1.1.12 Owing to its rapid vaporization and consequent lowering of temperature,
liquid LPG can cause severe frost burns if brought in contact with the skin.
Protective clothing such as gloves and goggles should be worn if exposure to
this hazard is likely to occur.
1.1.13 Like most light hydrocarbon vapours, LPG vapour is also slightly
anaesthetic and also cause suffocation if present in sufficiently high
concentrations.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

1.2.0 WHY AUTO LPG?

Use of LPG as automotive fuel is an age-old practice in various countries.

Over 10 million MT/ year of LPG is used as auto fuel in the world to-day. The
technology of conversion kit is proven and has been constantly upgraded with
the improvement in vehicle design in terms of fuel efficiency and emission
standards. In India, LPG has been officially recognized as an auto fuel in
2002 after amendment of all relevant Acts / Rules at Central and State levels.
Since then it has picked up great momentum and with the enthusiasm by
some of the State Governments in reducing pollution in cities and industrial
towns, motorists have chosen ALPG as a friendly fuel. Auto LPG conversion
in the existing vehicles is not only being done by the retro-fitters, the OEMs
have also come up with factory-fitted vehicles. This has become possible due
its inherent advantage in abetting environmental pollution, fuel economy and
customers preference.

1.2.1 ADVANTAGES:

ALPG is most economical fuel for petrol vehicles. At todays price, the
running cost is almost half of petrol.
Auto LPG meets BIS standard IS : 14861 which has Octane Number of 88
(minimum).
ALPG fitment in vehicles is safer than petrol system.
Smooth running and easy drivability.
Less pollution.
Easy availability in major cities and towns.

To sum up, ALPG is equivalent to CNG in emission characteristics and offers

petrol comfort with greater economy. ALPG is set to become the future fuel of
the country.
Industry ALPG volumes (000'KL)

300

250
FY 03-04
200
FY 04-05
150
FY 05-06
100
FY 06-07
50

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

1.3.0 WHY SHOULD WE NOT USE REMOVABLE LPG CYLINDERS IN VEHICLES

As per CMVR 115 C only fixed Auto LPG Tank with its safety
gadgets approved by CCOE are allowed in motor vehicles.
Use of cylinders other than approved ALPG fixed t ank is highly
unsafe and prohibited under law.
Auto LPG tank shall neither be replaced by domestic / commercial /
industrial LPG cylinder nor cylinders containing any other gases.

1.4.0 GENERAL INSTRUCTIONS FOR MOTORISTS

1.4.1 LPG being highly inflammable, any hot work (welding / gas cutting /
brazing etc.) on the body or other parts of LPG driven vehicle should be
done by trained staff at authorized work shop.
1.4.2 Repair of LPG tank is not permitted under any circumstances. However
repair / maintenance of Auto LPG system and its components should be
carried out at authorized workshops. Ideally, repairs should be done by
the same Retrofitter who has originally fitted ALPG system to the vehicle.
1.4.3 Auto LPG tank and the piping system should be checked regularly for
any leakage.
1.4.4 In case of serious leakage of LPG system, cut off LPG supply and park
the car in open area away from ignition sources. Move all the people from
the vehicle to a safe distance in an upward wind direction and seek
assistance of nearest authorized Installer / workshop.
1.4.5 Do not use domestic or any other moveable LPG cylinder as auto fuel as it
is prohibited under law and is highly unsafe.
1.4.6 Auto LPG re-fuelling to the vehicle tank should be done only at the
authorized ALPG Stations through the dispensing nozzle. Do not fill
domestic LPG or any other gas in ALPG tank.
1.4.7 After refueling LPG, please ensure that the dust plug is inserted back on
the filler valve.
1.4.8 It is recommended to run the vehicle 5-7 kilo meters in petrol mode after
every 100-150 kms run in LPG mode, to keep the petrol system in good
condition.
1.4.9 For carburetor engine, it is a good practice to put the selector switch in
neutral position for a while before switching over to LPG. Switching over
directly from petrol mode to LPG may lead to engine stalling or backfire
due to mixing of both fuels.
1.4.10 Never tamper with any of the components in the LPG system.
1.4.11 Any other safety recommendation by vehicle / kit manufacturer may be
followed.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

SECTION 2

ALPG CONVERSION KIT , ITS COMPONENTS AND FUNCTIONS

2.0.0 ALPG CONVERSION KIT

ALPG conversion kit is a complete system assembly for converting a vehicle to

run on LPG on bi- fuel mode. It has mainly three parts

( A ) ALPG tank with its accessories fixed in the boot of the car. For 3- wheeler
vehicles, the auto LPG tank is installed under the drivers seat.

( B ) LPG delivery System through VapouriserRegulator and Venturi Mixer.

( C ) LPG Control mechanism Closed loop system (ECU, Stepper motor/

Injector(s), Emulator & oxygen sensor etc) or open loop system (manual power
screw without any feed back mechanism

2.1.0 AUTO LPG TANK (ALT) AND ACCESSORIES :

Auto LPG tank is a

metallic cylinder or a
container of suitable
capacity for filling
LPG to be used as
fuel for Spark Ignition
( S.I ) motor vehicles.
The tank may be of
cylindrical or donut
shape to fit in the
vehicle space and
fixed rigidly to form
an integral part of the
vehicle. The tank
shall be approved by Chief Controller of Explosives under Gas Cylinders Rules
1981 and meet the requirements as per I S: 14899 (as amended from time to
time).

Unlike normal LPG cylinder, each auto LPG tank is fitted with a Multi- Function
Valve for protection of the vehicle system and safety of the passenger and
surroundings. It is an assembly for mounting on auto LPG tank for filling and
withdrawal of LPG along with safety devices including:

i. Automatic fill limiter

ii. Service valve
iii. Excess flow check valve

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

iv. Pressure Relief Valve

v. Fusible Plug
vi. Content Gauge
vii. Non-Return Valve on fill connect or

Multi Function Valve Assembly shall conform to latest Indian Standard

(amended from time to time) and approved by Chief Controller of Explosives
(CCOE).

2.1.1 AUTOMATIC FILL LIMITER: a provision in the filling system of the Auto
LPG Tank, which automatically terminat es filling when the liquid level in
the Auto LPG Tank has reached 80% of its volumetric capacity.

2.1.2 SERVICE VALVE: a manually operated or remotely controlled shut-off

valve fitted on the Auto LPG Tank wh ich c an open or shut off the LPG
supply.

2.1.3 EXCESS FLOW CHECK VALVE: a valve fitted on LPG outlet line which
closes automatically when a predetermined flow limit is exceeded by the
pressure drop. This is to safeguard against accidental rupture of LPG line
from the tank to the engine.

2.1.4 PRESSURE RELIEF VALVE: an automatic pressure relieving device,

communicating directly with the vapour space of the tank and pops off if
the tank pressure exceeds 22 kg / sq.cm. This is a safety valve to maintain
internal fluid pressure in the tank.

2.1.5 FUSIBLE PLUG: a device whic h melts at 110 - 120 deg C and allows the
product to vent out. It prevents the auto LPG tank from over
pressurization in the event of fire.

2.1.6 CONTENT GAUGE: gives visual indication of the level or quantity of the
LPG contained in Auto LPG Tank.

2.1.7 NON-RETURN VALVE: fitted on the LPG filling line which permits fuel to
flow in one direction only.

Multi Valve Assembly on the ALPG tank is fitted in a gas-tight chamber. It is

connected with a vent pipe wh ich is led to the outside of the vehicle and away
from the vehicle exhaust. In case of any leakage of gas from valve or popping off
of safety relief valve, LPG cannot enter the passenger space. It will be safely
vented out.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

2.2.0 LPG DELIVERY SYSTEM :

2.2.1 VAPOURISER REGULATOR

Vaporizer / Regulator is connected to the

radiator water circulating system. Liquid LPG
from the tank is vaporized by the hot water
from radiator and the regulator maintains the
output pressure and flow as required by the
engine.

2.2.2 VENTURI MIXER

The function of Venturi Mixer is to mix LPG vapour

with incoming air in correct proportion and supply to
the engine cylinder.

2.2.3 AUTOMATIC FUEL SHUT-OFF VALVE:

A solenoid valve for shutting off the supply of LPG from the
tank when ignition switch is put off.

2.2.4 SELECTOR SWITCH :

For switching over from petrol to LPG mode or vice

versa. It is located on the dash board.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

2.3.0 LPG CONTROL SYSTEM:

LPG control systems are of 2 types,- OpenLoop System and Closed-Loop

System.
Open-loop is the simplest form of conversion and does not need accurate
control. In this system LPG-air mixture is drawn by the vacuum signal before
it enters the cylinders.

2.3.1 EMULATOR :
is a buffer to absorb the
signals of petrol injection
when the car is running
on LPG mode in a MFI
engine. It works as a
dummy between petrol
and LPG.

2.3.2 STEPPER MOTOR :

It regulates the flow of LPG in the injection
system in MPFI engines based on signals
from ECU or Lambda Control. It has 216
steps and regulates the fuel flow accurately.

2.3.3 ECU or LAMBDA CONTROL :

It measures the oxygen content in the exhaust
stream and send signals to Stepper Motor to
control LPG flow.

ECU and Stepper Motor are essential

components of closed - loop system. The LPG
conversion kit needs to be duly tested and
approved by one of Testing Agencies mentioned
in Central Motor Vehicles Rules 126 in a bi-fuel
mode of LPG / petrol or dedicated mode of LPG.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

SECTION 3

CHECKLIST FOR INSPECTION OF

LPG VEHICLES (NEW AND IN-USE)
(OTHER THAN LPG BUSES) BEFORE REGISTRATION BY REGISTERING
AUTHORITY

This checklist is for inspection of LPG vehicles (other than LPG Buses) i.e. three and
four wheeler etc before registration by RTOs. Reference to relevant clauses of Safety
Code of Practice, e.g. A IS 026/AIS 027 as the case may be, and guidelines issued by
Central Government from time to time should be made wherever appropriate.

3.1.0 Details of LPG Vehicle

3.1.1 OE Vehicle manufacturer / Supplier.

a. Name and address
b. Name and address of Retrofitter.

3.1.2 Name of type approval agency ARAI / IIP / VRDE/ test agency
approved by Central Govt.from
time to time

3.1.3 Type approval

a. Reference number of type approval certificate
b. Validity of certificate

3.1.4 Chassis and engine No.

a. Original as per RCTC
or
b. New in case replacement of engine

3.1.5 Vehicle details

a. Registration No:(if applicable)

b. Vehicle type , make & model

c. Year of manufacture of Vehicle

d. Month & year of conversion

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

3.2.0 Detail of LPG System

Checking Auto LPG Tank (s)(ALT) as per CCOE

/ Vehicle Testing Agency approvals ( ARAI / IIP /
VRDE )
a. Make of ALPG tank
b. Capacity, lit
c. Type approval certificate
d. Hydro-test of tank

3.2.1 Tank Installation

Safety checks
a. Check for corrosion on any LPG components /
mountings of gas circuit
b. Check whether ALT is securely mounted within
the vehicle and check tightness of nuts and bolts
c. Check whether minimum 5 mm clearance is kept
between ALT and vehicle body structure.
d. Distance between ALT valve and vehicle body
extremities shall not be less than 200 mm
unless valves are protected
(as per the details provided by the kit/vehicle
manufacturer/kit supplier and duly vetted and
approved by test agencies ) to minimize the
possibility of damage due to collision,
overturning/ other accident.
e. Check whether ALT is correctly oriented ( using
angle finder if required) as specified in type
approval certificate for base model (i.e. 0 / 30 /
90 etc w.r.t. horizontal plane)
f. In case the model being inspected is other than
the base model for which the type approval has
been given and is covered by the flexibility clause
of +/- 25%, check if it has got the layout approval
or change of orientation, if any.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

g. Check for reinforcement if ALT is mounted on

floor of the vehicle (minimum dimension of
reinforcement thickness & surface area shall not
be less than 2.5 mm & 3600 mm2 respectively).
h. Check for packing (as approved by test agency)
provided for inner side of the ALT mounting
band(s).
Notes:
Rubber pack ing if found damaged during inspection it should
be replaced by the new material having revised specification

3.2.2 Multi function Valve

a. Check specific type & model approved by Vehicle
Testing Agency for the vehicle under inspection.

b . Check for operation of solenoid valve

c. Check for physical damage / distortion to valves (visual
inspection)
d. Check for the vent pip e outlet routing away from exhaust
in case of ALT fitting in t he enclosed compartment.

3.2.3 Refilling Valve

Safety checks
a. Check the position as per layout.
b. Check for dust cap to be present

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

3.2.4 Fuel Line Safety checks-

a. Check for corrosion, deformation and damage

on LPG fuel line .
b. In case of PVC sleeved fuel line , corrosion shall
be inspected at the ends, wherever it is
exposed. Also inspect for any damage to the
sleeving. Sleeve should be firmly gripped to the
LPG fuel line.
c. Check whether fuel line is securely mounted.
d. Check for U and Pigtail bends provided in high
pressure piping for flexibility as per approved
layout.
e. Check whether effective protection is provided
,as per approved lay-out, to prevent the
possibility of damage due to loose objects from
road.
f. Distance between fuel line and exhaust pipe /
shield shall not be less t han 75 mm and the fuel
line should also be properly clamped and route d
so as not to touch the engine block.
g. Check the distance between any two clips
which shall not be more than 600mm (500mm
incase of 3 wheeler respectively).

3.2.5 Shut Off Valve (Solenoid Valve(s)) wherever

separately provided
Safety checks

Check operation for Close & Open(electrical

activation) as required

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

3.2.6 Regulator
Safety checks

a. Verify the following as per type approval specification

Make
Type(if applicable)
Identification No

b. Check whether regulator is securely mounted

c. Distance between regulator & exhaust should be
more than 100mm.

3.2.7 Gas-Air Mixer

Safety checks

a. Verify the following as per type approval specification

Make
Type(if applicable)
Identification No

b. Check whether gas-air mixer is securely mounted

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

3.2.8 Electrical Wiring

Safety checks for OE & in-use vehicles -

a. Check whether that current limiting device (fuse) is

fitted as per manufacturer specifications and make .

b. Terminals are insulat ed to prevent shorting.

c. Wiring are taped and clipped with loom & mounted

securely.
d. Battery shall be securely mounted and battery
terminal shall be locked properly by means of
suitable nut & bolt with washers.
e. Check installation of battery cut-off switch as per
vehicle / chassis manufacturers recommendations
(if applicable). Location of Battery cut-off switch
should be within the reach of driver in seating
posture in driving seat.
f. Check routing of high tension cable to avoid
accidental earthing and to be placed away from
any heat source as per Vehicle / chassis
manufacturers recommendations / layout or as
approved by Test Agency.
g. Check for proper make of high tension cable
connected to Spark Plug as per Vehicle/chassis
manufacturers recommendation. Check for tight
fitment of its terminal to the spark-plug.

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 Booklet on Safe Practices /Check List for LPG Operated Vehicles

3.2.9 Automatic fill limiter(AFL):

a. Check operation of AFL for maximum 80% filling
of LPG( if required)
Note: This test is to be performed randomly on vehicle
to inspect at dispensing station. This will ensure
effectiveness of. safety
3.2.10 LPG Filter: (wherever separately provided)
a. Check whether LPG filter is securely mounted

3.2.11 Compliance Plate:

InstallationCheck

Check for following Details for no. of ALTs

1 2 Remark
a. ALT identification No.
b. Date of last testing and the name of
certifying agency
c. Water capacity (ltr)
d. Next due date of testing
e. Water capacity (ltr) of total installation
f. Vehicle registration/ identification No.
(to be furnished after registration)
g. Check whether compliance plate is
installed near filling connection & be
clearly visible to the filling agency

3.2.12 Identification label in front and rear:

a. Located on left side of the front and rear safety
glass and shall Check whether visibility from front
and rear sides

3.2.13 Compartment/Sub-compartment/Gas tight

housing(for internally mounted ALT/s)
a. Check whether Compartment / Sub-comparment
Gas tight housing is in good condition i.e. shall not
show any crack/damage.

15
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

b. Check whether it is firmly clamped to the

conduit/vent hose/ducting

3.2.14 Conduits/ducting (for internally mounted

ALT/s)
Check whether Conduits/ducting is in good
condition i.e. shall not show any crack/damage
3.2.15 Petrol Shut Off Valve (Solenoid) (if
applicable i.e. Gasoline injection vehicle
does not require such solenoid valve)
a. Check operation
b. Check whether service shut off valve (petrol) is
securely mounted
c. Leak test (visual inspection)
d. Verify the make & type as per the Type Approval
specification.

3.2.16 Fuel selection switch (for bi-fuel mode) &

indicator for LPG content.
Check operation

3.2.17 Low pressure hose

Check for kinks, damage or abrasion to the cover

3.2.18 High Pressure pipe

Check for any damage / crack at the bends.

3.2.19 Catalytic Converter

Specification of catalytic Converter fitted on vehicle shall be
verified as per type approval specification.

3.2.20 ECU ( Lambda Control with Emulator )

Specification, make, model & ID No. of ECU shall be verified as
per type approval specification.

16
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

FORM B.T.I.
Maharashatra Motor Vehicle Rules, 1959
{See Rules 65 (1) }
Notice in regard to an alteration in a Motor Vehicle
To,
The Registering Authority
Dy./ RTO ..
I am Owner of the Vehicle having following description.
M.V. No. ... Make... Model............................
Type.. Fuel.. U.W..Kg. RLY................Kg. ............

Document of the Vehicles are as below:

Tax is paid up to..Insurance valid upto........................................

Permit No.Valid upto...................................

C.F. Valid upto.....................................

The vehicle is converted with HPA / HPY of .
I have enclosed N.O.C. to do the necessary changes for financier (If covered with HPA /
HPY) or Not covered with HPA / HPY.
I intends to retorfit LPG Kit make..approved by (VRDE /ARAI)vide letter
No.dt..as per Transport Commissioner's office letter No. ............
............... dt.........................Workshop . (Name of workshop)

Approved as per Transport Commissioner's office letter No. ........................................

..........dt / /
I will produce the vehicles within 14 days for inspection before you, after conversion.
The above information is true.
Date: Signature of the Owner
.....
Approved kit for the said model is available

Signature of Retrofitter
.

(for use of the Regional Transport Office only)

Approval is here by Accorded / Refused for making the requested alteration with reasons given below.
......................................................................................................................
......................................................................................................................

17
 Booklet on Safe Practices /Check List for LPG Operated Vehicles

Submitted
M.V. No. ................... Class: ...Date..............

Produced duly retrofitted with L.P.G. Conversion System of following description.

Date of retrofitment.......................
A) Name & address of the Retrofitter

B) Name of the Conversion System

C) L.P.G. Kit make & model:.....Kit Sr. No..............

Approval order No. & date :...................,
Approving Agency:.......................
D) Gas cylinder make:............ Cylinder Sr. No.............

Water capacity of the Cylinder :......................

Chief Controller of Explosive's Certificate testing for cylinder testing

Outward No. :.................Dated..........

E) Fee Rs. 50/-........Dated.....................................

F) Unladed Weight......... Kg. :..........

Enclosed
1) Installation Certificate
2) CCOE Certificate for Cylinder
3) PUC Certificate
4) Unladed Weight slip
5) Chassis No. of Vehicle & Cylinder Sr. No. Kit No., Pencil Prints attached.

It approved office record may be fitment of L.P.G. Kit

Signature of Inspector of Motors Vehicles

Note : A,B,C,D,E,F, in RC and Record.

Signature of Registering Authority

Note taken

Signature of Jr. Clerk Signature of Head Clerk

18
 Regional Transport Office.................................................................... Regional Transport Office....................................................................
M.V. No....................LMV/Auto Rickshaw............................................ M.V. No....................LMV/Auto Rickshaw............................................

to to

s. s.

Regional Transport Office:............................................ Regional Transport Office:............................................

Booklet on Safe Practices /Check List for LPG Operated Vehicles

19
20
LPG INSTALLATION - SCHEMATIC DIAGRAM

GAS GREEN
AIR OUTLET
FILTER
GAS
6
STEPPER M
GAS AIR M
MOTOR C
MIXER O
P
P
E
R
WATER VAPOUR BOX
& MULTI VALVE
WATER
ENGINE GAS LPG TANK
FILLER
CATALITIC SOLENOID VALVE
CONVERTOR ASSEMBL 10 MM COPPER
O2
LEVEL GAUGE PIPE/DUCTING
SENSOR
INDICATOR VENTILATION

PETROL
TANK
JU
Booklet on Safe Practices /Check List for LPG Operated Vehicles

ST PETROL
+ 12V
SOLENOID
CHANGE
JUST OVER SWITCH
Members & Associates

alternative fuel systems

21
 Members & Associates

H A L D I A
GAS EQUIPMENTS PETROCHEMICALS LTD
Your Environment Guardian

WORLD LP GAS ASSOCIATION Progress through Research

22
 Office Bearers & Executive Committee

President Vice President

John Joseph S Samant
Sr. V P- Reliance Industries Ltd. Dy. General Manager
[email protected] Indian Oil Corporation Ltd
[email protected]

General Secretary Hony. Vice President

Suyash Gupta Sunil Mathur
Managing Director World LPG Association
CleanFUEL India Autogas Pvt. Ltd. [email protected]
[email protected]

Treasurer Chairman Training Committee

Shishir Agrawal Shrikant Marathe
Managing Director Director
CLH Gaseous FuelApplications Pvt. Ltd. Automobile Research Association of India.
[email protected] [email protected]
(Chairman-Projects Committee)

Member - Executive Board Chairman- OE Committee

Amit Shah K K Gandhi
Managing Director Director- Technical
Ace LPG Kits (P) Ltd Society of Indian Automobile
[email protected] Manufacturers
[email protected]

23
 Office Bearers & Executive Committee

Member - Executive Board Founder Patron

S K Hazra Balraj Bhanot
Managing Director (Former Chairman, CMVR Technical
Aegis Logistics Ltd. Committee & Former Director,ARAI)
[email protected] [email protected]

Member - Executive Committee Member - Executive Committee

Rajiv Chohan Pradeep Rungta
Managing Director Director
Shell Gas (LPG) India Private Limited Vialle Alternative Fuel Systems (P) Ltd
[email protected] [email protected]

Member - Executive Committee Member - Executive Committee

V N Diwakar A K Goel
Vice President Bharat Petroleum Corporation Ltd
Business Development and Special [email protected]
Projects
SHV Energy Private Limited
[email protected]

Member - Executive Board

K. Balakrishnan, Regional Director
United States-Asia Environment
Partnership,
US Embassy, Chanakyapuri, New Delhi
[email protected]

24
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Member

WORLD LP GAS ASSOCIATION