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    Safety Checklist For Compressed Natural Gas

    Uploaded by

    Seyi Ogunremi
    1. The document provides safety guidelines for vehicles powered by compressed natural gas (CNG), including inspecting CNG kits and cylinders, checking for leaks, proper parking, and emergency procedures. 2. Key safety measures include using only approved CNG kits, checking that cylinders are properly secured and valves are intact, and ensuring gas lines are supported and free of leaks. 3. In emergencies like gas leaks or fires, the document instructs drivers to evacuate the vehicle, avoid ignition sources, and shut off the gas if possible before seeking help.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Safety Checklist For Compressed Natural Gas

    Uploaded by

    Seyi Ogunremi
    279 views5 pages
    1. The document provides safety guidelines for vehicles powered by compressed natural gas (CNG), including inspecting CNG kits and cylinders, checking for leaks, proper parking, and emergency procedures. 2. Key safety measures include using only approved CNG kits, checking that cylinders are properly secured and valves are intact, and ensuring gas lines are supported and free of leaks. 3. In emergencies like gas leaks or fires, the document instructs drivers to evacuate the vehicle, avoid ignition sources, and shut off the gas if possible before seeking help.

    Original Description:

    Summary of checklist for for safety in CNG handling.

    Original Title

    SAFETY CHECKLIST FOR COMPRESSED NATURAL GAS

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    1. The document provides safety guidelines for vehicles powered by compressed natural gas (CNG), including inspecting CNG kits and cylinders, checking for leaks, proper parking, and emergency procedures. 2. Key safety measures include using only approved CNG kits, checking that cylinders are properly secured and valves are intact, and ensuring gas lines are supported and free of leaks. 3. In emergencies like gas leaks or fires, the document instructs drivers to evacuate the vehicle, avoid ignition sources, and shut off the gas if possible before seeking help.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    279 views5 pages

    Safety Checklist For Compressed Natural Gas

    Uploaded by

    Seyi Ogunremi
    1. The document provides safety guidelines for vehicles powered by compressed natural gas (CNG), including inspecting CNG kits and cylinders, checking for leaks, proper parking, and emergency procedures. 2. Key safety measures include using only approved CNG kits, checking that cylinders are properly secured and valves are intact, and ensuring gas lines are supported and free of leaks. 3. In emergencies like gas leaks or fires, the document instructs drivers to evacuate the vehicle, avoid ignition sources, and shut off the gas if possible before seeking help.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 5

    SAFETY CHECKLIST FOR COMPRESSED NATURAL GAS (CNG) VEHICLES

    SAFETY MEASURES

    • Always use an approved CNG kit & cylinder. It is dangerous and illegal to use
    substandard cylinders 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 for 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 supplier’s manual for operating instructions and do not do
    trouble-shooting yourself, other than that recommended by the manufacturer.
    • Be aware of the location and operation of the cylinder valve, master shut-off valve, and
    burst disc in the CNG system.
    • Ask your mechanic to identify these parts for you. It would be helpful for emergency
    handling of any CNG leak.

    SAFETY CHECKS

    • Make sure that the 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

    • Check out of the vehicle.


    • Do not start the vehicle. Push vehicles to a place outside the station in open Air.
    • Stop all activities in the vicinity, which can provide a 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

    • Evacuate the vehicle and surrounding place.


    • Take help of firefighting experts – 101.
    • 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

    • Endorsement of CNG mode in Registration Certificate.


    • Hydro testing of the cylinder, once in 3 years, as per Gas cylinder rules, 2004.
    • Certificate of CNG Kit, Fitness and hydro test to be possessed by the driver all the time.
    • Maintain cylinder in good condition.
    • No repair to be done on cylinder and valves. No oil, Grease or lubricant to be used for
    cylinder.
    • Don’t change the colour of the cylinder.

    Vehicular Use of Compressed Natural Gas

    1. Check your cylinder and kit certificate.

    • The workshop issues a safety certificate after the kit fitment that the conversion kit has
    been in safe and proper manner.
    • The dealer issues a certificate stating the details of cylinder make and number and re-
    testing date.

    All CNG users need to carry their fitment certificate for filling CNG.

    2. Use only approved CNG kits.

    • Use only CNG kits approved by the Automobile Research Association of India (ARAI),
    Pune, Vehicle Research and Development (VRDE), Ahmednagar or India Institute of
    Petroleum (IIP), Dehradun.
    • Install your CNG kits at a workshop authorised by kit supplier or manufacturer.
    • Install CNG cylinders approved only by Chief Controller of Explosives.
    • CNG cylinders are required to be tested and certified for use after every five years.

    3. Do not try to source the kit components separately.

    • Do not make the CNG kit yourself as non-compatibility of components could be unsafe.
    • Usage of spurious cylinders is an offence.
    • Ensure your CNG conversion is authorised by the Regional Transport Authority.

    4. CNG vehicles may be parked, serviced and repaired inside garages provided following
    conditions are observed.

    • There should be no leaks in the fuel system.


    • These vehicles should not be parked within 6 m of any source of ignition or fire
    • Cylinder shut-off valve and service valves should be closed and CNG fuel in the service
    line exhausted by running the engine or depressurising the line in a well-ventilated area.
    • In case of vehicles undergoing repairs involving any hot work (i.e., welding, gas cutting
    or any type of heat application to any part) within 1.5 m of the cylinder, the cylinder
    should be removed first.

    5. Periodical inspection, testing schedule of CNG equipment and components.

    • After initial conversion, the vehicle may have to be brought to the workshop for tuning
    on gas after 1,000 to 1,500 km as diaphragms and other parts require this much usage
    before settling down.
    • As specified under the law by the Chief Controller of Explosives, the CNG cylinder must
    be hydraulically tested and certified by an authorised 'testing shop' once in every five
    years.
    • In addition, the vehicle user is required to take the vehicle for annual inspection to a
    'CNG Conversion Workshop', and obtain a certificate from the workshop that the CNG
    system, which has been installed, is satisfactory. It is necessary to produce this certificate
    at the time of CNG filling.

    H.1. Dos and Don'ts


    1. In case of an accident, get the vehicle thoroughly checked at an authorised workshop and
    obtain a fresh certificate.
    2. Don't smoke or bring any source of flame near any of the components through which
    CNG is passing.
    3. Don't park the vehicle in a non-ventilated area.
    4. Handle all the valves and parts with due care. Any mishandling may flatten the CNG
    piping.
    5. Do not install an LPG, propane or any other cylinder in the place of CNG cylinder. It is
    not only illegal but also unsafe.
    6. For emergency handling of any CNG leak, users must be aware of the location and
    operation of the cylinder valve, master shut-off valve and the burst disc in the CNG
    system.
    Inspection Intervals Defined by U.S DOT’s FMVSS 304

    • All CNG cylinders must be inspected after any fire or accident, regardless of vehicle
    GVWR.
    • For vehicles with GVWR of less than 10,000 pounds, CNG cylinders must be inspected
    at least every 3 years or 36,000 miles, whichever comes first.
    • For vehicles with GVWR of 10,000 pounds or greater, CNG cylinders must be inspected
    at least every 12 months

    Four Types and Intervals for Inspections


    Inspection Inspection What is Who
    When Performed?
    Type Level Inspected? Performs?
    Thorough
    inspection of all A certified or
    Detailed
    Pre-Service high pressure qualified CNG
    Prior to placing vehicle in service Visual
    Inspection components, Fuel System
    Inspection
    including Inspector
    cylinders
    Driver Pre-
    Cursory All visible
    and Post- Before and after each trip in a
    Visual components and Driver
    Trip CNG vehicle
    Inspection cylinder shields
    Inspection
    All visible
    General General components, with Trained
    During any preventive
    Visual Visual special attention Vehicle
    maintenance/service
    Inspection Inspection to cylinder Technician
    shields
    After any fire or accident. Thorough
    Vehicles <10,000 pounds GVWR inspection of all A certified or
    Detailed Detailed
    at least every 3 years/36000 miles, high-pressure qualified CNG
    Visual Visual
    whichever come first. Vehicles components, Fuel System
    Inspection Inspection
    10,000 pounds GVWR or greater including Inspector
    at least every 12 months cylinders

    What Is Covered in the Detailed Visual Inspection?

    In 2008, the NGV industry adopted a best practice to inspect not just the cylinders, but the entire
    high pressure CNG fuel system. This includes:

    • Fuel Receptacle
    • Secondary Check Valve
    • Defueling System
    • Fittings, Tubing and Lines
    • Cylinder(s)
    • Cylinder Shields and Mounting System
    • Cylinder Valves

    • PRDs, Vent Lines and Caps


    • Fuel System Isolation Valve
    • High Pressure Coalescing Filter
    • Fuel Shutoff Solenoid
    • Pressure Gauge
    • Pressure Regulator
    • Components/Labels

    What Records are Required?

    For each Detailed Visual Inspection, a completed CNG Fuel System Inspection form and
    accompanying photos should be retained. Inspection records are not required to be submitted to
    any regulatory agency or manufacturer.

    At the conclusion of each Detailed Visual Inspection, a “Passed” or “Failed” inspection label
    should be affixed to each cylinder installed on the vehicle.

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