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Finalized Draft AIS-024 SAFETY AND PROCEDURAL

1. e Safety checks Verify the following as per type approval specification gt Make gt Type if applicable gt Identification No Check whether gas air mixer is securely mounted Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 34 8 3 a 8 Electrical wiring Safety checks 8 1 FOR OE amp CONVERTED RETROFITTED IN USE VEHICLES Check whether that current limiting device fuse is fitted as per manufacturer specifications and make Terminals are insulated to prevent shorting Wiring are taped and clipped with loom amp mounted securely Battery shall be securely mounted and battery terminal shall be locked properly by means of suitable nut amp bolt with washers Check installation of battery cut off switch as per vehicle chassis manufacturer s recommendations if applicable Location of Battery cut off switch should be within the reach of driver in seating posture in driving seat Check routing of high tension cable to avoid accidental earthing and to be placed away from any heat source as per Vehicle chassis manufacturer s recommendations layout or as approved by Test Agency Check for proper make of high tension cable connected to Spark Plug as per Vehicle chassis manufacturer s recommendation Check for tight fitment of its terminal to the spark plug FOR OE VEHICLES Check wiring harness layout under the floor and
2. 6 Regulator Safety checks Verify the following as per type approval specification gt Make gt Type if applicable gt Identification No Check whether regulator is securely mounted Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 7 Gas Air Mixer Safety checks Verify the following as per type approval specification gt Make gt Type if applicable gt Identification No Check whether gas air mixer is securely mounted Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 22 8 Electrical wiring Safety checks 8 1 FOR OE amp CONVERTED RETROFITTED IN USE VEHICLES a Check whether that current limiting device fuse is fitted as per manufacturer specifications and make b Terminals are insulated to prevent shorting c Wiring are taped and clipped with loom amp mounted securely Battery shall be securely mounted and battery terminal shall be locked properly by means of suitable nut amp bolt with washers e Check installation of battery cut off switch as per chassis manufacturer s recommendations 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 chassis manufacturer s rec
3. NOTE If wheel base measurement falls between any of the figures shown above then the next highest figure is to apply 72 APPENDIX G BACKFIRE DEFLECTOR TESTS 1 2 3 4 5 6 7 8 A backfire deflector under backfire conditions shall contain a visible flame front within its confines and shall not be displaced physically damaged or distorted or show evidence of burning or smoldering of internal parts If the deflector is of the oil bath type it shall be free of any overflow or discharge permitting accumulation of oil on electrical hot engine or exhaust system parts A complete industrial truck vehicle is to be used for this test Tests are not required on backfire deflectors employed diesel engines The backfire deflector air cleaner oil bath or dry element type and connecting hose are to be removed from the engine The spark timing is to be advanced approximately 8 degrees and the spark plug leads are to be interchanged to obtain sharp backfires under the following conditions The engine is to be alternately raced and idled and the ignition switch is to be operated to alternately energize and de energize the ignition system During the test the intensity of the backfire and the issuance and extent of the accompanying flame are to be noted The backfire deflector air cleaner is then to be installed on the truck in the intended location An oil bath type deflector air cleaner is to be filled t
4. 4 2 3 2 The regulator assembly shall not be attached to the engine assembly unless otherwise specified by the manufacturer and then shall be fitted only in accordance with the manufacturer s recommended instructions 4 2 4 The gas air mixer 4 2 4 1 There shall be installed in the air intake immediately prior to the mixer a backfire deflector to arrest flash back which shall meet the requirements of Appendix G of this standard In case of heavy motor vehicle there shall be installed in the air intake prior to the mixer a backfire deflector original air filter acceptable In turbo charged applications where rigid piping is fitted from the turbo charger to the intake manifold a pressure relief valve shall be fitted as close as practicable to the intake manifold Where a volume of gas air mixer due to turbo charging or inter after coolers is contained downstream of the mixer special precautions will need to be applied to avoid damage to components downstream of the mixer due to backfire Vehicle manufacturer kit manufacturer kit supplier shall submit test report or certificate complying with the above requirement It is not necessary to carry out the test if declaration is submitted 4 2 4 2 The mixer shall be securely mounted and when remotely fitted shall be suitably bracketed to support its own weight and applied working forces 4 2 4 3 There shall be no air filter element fitted downstream of the gas air mixer 4 2 5 Dual f
5. The kit installer shall ensure compliance to the emission norms and Sub rule 2 of Rule 115 and the code of practice for the use of CNG fuel in internal combustion engined vehicles Responsibility of the vehicle kit manufacturer supplier installer The owner driver shall be instructed in the correct way the gas system and controls function along with a owners operation manual for the gas system outlining the following 15 1 Basic gas system explanation with a diagram 15 2 Fuel change over switch operation if bi fuel Dual fuel system is fitted 15 3 Starting procedure for cold and hot starting 15 4 How the vehicle is refueled 15 5 In the event of backfiring check procedure 15 6 In the event of a gas leak shut off procedure 15 7 Emergence or information contact numbers Annexure VI Page 1 2 INSTALLATION CERTIFICATE FOR CONVERTED CNG VEHICLE DEDICATED BI FUEL DUAL FUEL to be filled in by installer A Details of Installer Approval 1 Installation Certificate issued by Name and address of installer 2 Approval of installer Name of vehicle manufacturer kit manufacturer kit supplier who has approved the installer cas Type of vehicle converted As per AIS 053 Approval of the CNG kit a Name of the Test Agency b Approval Certificate No amp Date Details of Converted Vehicles Regn No amp year of manufacture Chassis and engine No WM es Type of Operation Bi fu
6. 14557 Any other tests as made applicable by y y y Government of India from time to time Annexure X b Tests to be carried out by Test Agency For Retrofitment of In Use Vehicle CNG Dual Fuel Engine Performance Tests to be carried out For In use For Retrofitment For retrofitted by Test Agency as per applicable Gasoline Modification of Dual Fuel CMVR prevailing in the year of Vehicles In use Diesel CNG Vehicles manufacture of vehicle model Vehicles Mass emission test y y y Engine performance test y y Constant speed fuel consumption test y y Ve as applicable Gradeability test NA y y EMI EMC test as notified by NA y y Government of India from Time to time Range test of atleast 250 km for buses NA y y Cooling performance test as per IS NA y 14557 Any other tests as made applicable by y y y Government of India from time to time 39 Annexure X c Tests to be carried out by Test Agency For Replacement of In Use Diesel Engine by New CNG Engine Performance test to be carried out by Test Agency For Replacement of In use Diesel Engine by New CNG Engine Dual Fuel Engine Mass emission test y Engine performance test y Constant speed fuel consumption test K as applicable Gradeability test y EMI EMC test as notified by y Government of India from Time to time Range test of atleast 250 km for buses y Cooling performance
7. Safety glass 8 Horn 9 Silencer 10 Sari guard passenger hold 11 Dash board equipment 12 Windshield Wiper 13 Exhaust emission 14 Brake 15 Speedometer 16 Steering 17 Seat Belt 18 Suspension springs viz a No of leaves b Size of flat width and thickness front and rear 19 Tyre viz a Size ply rating b Condition of Tyre new remoulded c Tread depth 20 Location of exhaust pipe 21 Overall Dimension viz a Length b Height c Width d Overhang 22 Structural Integrity a Changes to the chassis vehicle body 23 Visual inspection of propeller shaft and universal joint to be carried out Vehicle Model Engine No Year of manufacture Chassis No Vehicle Registration Identification No Name of the Kit Installer Signature with Seal Name Designation Document No indicating also revision status Date Sheet No of Mention NA Wherever not applicable INDIAN GAS CYLINDER RULES 2004 as amended from time to time Annexure IV Page 1 2 SAFETY CHECKS FOR USE OF CNG FUELS IN INTERNAL COMBUSTION ENGINED VEHICLES AS PER AIS 028 amp Sr CNG Kit Component Certifying Verifying Authority Clause of AIS 028 No Other Rules Standards etc 1 Cylinder PESO Nagpur to certify or endorse in Gas cylinder rules case of foreign make 2004 1 1 Fitment of cylinder o
8. T GRATER A HAN 9b IN LU DED ANGLE 11 O ring seal DUST PLUG OUST PLUG CNG VEHICLE FILLING SYSTEM 70 APPENDIX E FREEZING CONDITIONS AND CORROSIVE CONDITIONS El Where Regulator heat is drawn from the engine cooling water care should be taken to ensure that the water PESOs not freeze in the Regulator during cold weather Expansion of the water on freezing can cause serious damage to the pressure regulator assembly E2 Most CNG Regulators are made from non ferrous alloys which can suffer pinhole corrosion under certain conditions If this is allowed to take place CNG can be admitted to the cooling water system where it will pressurize the radiator and cause a potential hazard It is important therefore to have an effective anticorrosion additive present in the cooling water E3 It is important to ensure that the coolant additive and the dilutant ratio comply fully with the engine manufacturer s requirements 71 APPENDIX F TABLE FOR USE WITH CLAUSE 2 3 3 2 AND FIG 1 ZONES OF CLEARANCE Wheel base mm 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 Clearance height at 17 ramp angle point A of fig 1 mm 134 142 149 157 164 172 179 187 194 202 209 216 224 231 239 246 254 261 270 276 284 291 298 306 313 321 328 336 343 351 358 366 373
9. between cylinders and an engine shall not pass between a towed and a towing vehicle unless the following conditions are satisfied 53 3 4 1 a b c d e g Low pressure transfer of CNG The cylinder pressure shall be reduced to value not greater than 2 15 MPa by use of a primary regulator placed upstream of the towing connection All such equipment should be recommended for this application by the equipment manufacturer All components downstream of the primary regulator must be protected against pressure rise due to failure of any other component by the use of a relief valve which will prevent the pressure experienced downstream of the primary regulator from rising above 3 3 MPa CNG fuel line connecting the towed and towing vehicle shall be flexible hose and shall meet the requirements of SAE 100R1 The flexible fuel line shall be arranged and installed so that the free movement of the hose between towed vehicle and the breakaway coupling shall be minimum required to accommodate all possible movement with the towing coupling engaged A breakaway coupling shall be provided within the connection of the flexible hose between towed and towing vehicle and the rigid fuel line installed on the towing vehicle The coupling shall be attached to the towing vehicle in such a manner so as not to impede its operation and shall resist without permanent deformation of the attachment a proof load of 50 kgf in the forward an
10. every day before starting and bringing on road Distance between the exhaust line muffler and fuel line shall be a minimum of 75 mm If not a radiant heat shield of 2mm thickness shall be welded in between Safety plates shield below the pipe joints shall be welded and proper inspection windows shall be provided near the cylinder joints Check for First Aid kit as per CMVR Minimum two copies of safety instructions shall be displayed in passenger compartment Any other preventive safety recommendations provided or advised by chassis manufacturers retrofitters to be complied with Note The instructions issued by OE manufacturer retrofitter for preventive maintenance in their instruction manual shall contain all the necessary details on the methodology amp the procedure for carrying out these checks Signature amp Seal with Date 30 Annexure IX CHECKLIST FOR THIRD PARTY CHECKING INSPECTION OF CNG VEHICLES OTHER THAN CNG BUSES BEFORE REGISTRATION NEW AND CONVERTED RETROFITTED IN USE DEDICATED BIFUEL DUALFUEL This checklist is for third party inspection of CNG vehicles other than CNG Buses i e two three and four wheeler etc before registration by RTOs Reference to relevant clauses of Safety Code of Practice e g AIS 028 and guidelines issued by Central Government from time to time should be made wherever appropriate A Details of CNG Vehicle 1 a Name and address of OE Vehicle m
11. exception being flexible hose designed for and used between the towed and towing vehicle 3 1 4 Joints and connections 3 1 4 1 Every joint or connective filling in rigid high pressure fuel line shall be tested for minimum test pressure of 70 MPa without leakage or failure 3 1 4 2 The number of joints and connections shall be the minimum for the inclusion of all components 3 1 4 3 Joints or connections in a CNG fuel line shall be in accessible positions for easy inspection 3 1 4 4 Connection means shall provide positive retention of the fuel line in the fitting e g by double inverted flaring of the tube end 3 1 5 Securing and location 3 1 5 1 High pressure piping and hoses in vehicles shall comply with the following a No CNG fuel line inside the part of any vehicle occupied by the driver or passenger shall be outside the sealed and vented enclosure except as provided for in 2 4 3 b All CNG fuel lines shall be positioned for protection from the possibility of damage by impact accident or loose objects thrown by the vehicle wheels tyres Parts of the vehicle may be used to provide such protection c CNG fuel lines shall not be located inside box sections or in other inaccessible locations nor shall they be installed in any location which is not adequately protected from sources of heat abrasion or from impact 52 d Use of the drive shaft tunnel for fuel line location is not desirable or recommended If such
12. in a position beneath the vehicle that decreases the effective ground clearance c Incase of heavy vehicles bus having more than 3 5 GVW for fitment of cylinders on roof the strength of roof shall be validated by testing agency based on design calculation provided by vehicle manufacturer kit manufacturer kit supplier Refer to fig 1 for 4 wheeler below 3 5 tonnes GVW 2 3 3 Vehicle mounted cylinders 2 3 3 1 A cylinder installed in a vehicle shall be permanently mounted and filled in that position 2 3 3 2 Cylinder location ground clearance Cylinders shall be located in accordance with all the following requirements a The vehicle mass for determining ground clearance shall be the laden mass including permanent non standard attachments to the vehicle with all fuel water and oil containers full b Cylinders installed between and behind axles shall not be lower than the lowest of the following points and surfaces forward of the cylinder refer figure 1 for 4 wheeler below 3 5 tonnes and figure 2 for 4 wheeler and above exceeding 3 5 tonnes GVW i The lowest structural component of the body 11 The lowest structural component of the frame or sub frame if any 11 The lowest point of the engine 1v The lowest point on the transmission including the clutch housing or torque converter housing as applicable but excluding differential housings v The original fuel tank or tanks and or brackets vi Approach and d
13. integrity during the test c Hatches covers or construction joints which may need to be opened or dismantled during maintenance or inspection shall be capable of being opened at least 10 times without adverse effects on durability Hinges and locking devices of hatches and covers shall be designed to prevent the dislodgment of the hatch or cover when in the closed and locked position d The construction shall be such that when subjected to a pushing force of 60 kgf applied at any point on any external face of the sub compartment any resultant damage shall not be of a nature to permit gas leakage in the event of pressure testing as in b above The pushing force shall be applied by a measuring instrument having a flat circular face of 20 mm diameter It shall be possible to operate the cylinder service shut off valve in the installed position The valve may be arranged so that it can be operated from some internal area of the vehicle provided e wma 47 that the sealing of the compartment or sub compartment shell is maintained by one of the following means as appropriate i If a valve actuating device passes through the shell a gas tight seal shall be provided 11 If the actuating handle is wholly within the shell access shall be a gas tight captive hatch The design shall not need tools to open the hatch f A compartment or sub compartment shall not contain ignition sources or electrical equipment or wiring unless it i
14. kit supplier to provide at least two total minimum area of 450 sq mm vent pipes connecting the under floor of the vehicle to the rooftop for CNG gas to vent out in case of leakage The vent pipes to be located close to the cylinder valves cluster as per recommendations of chassis manufacturer Construction should be such that leakage into passenger compartment is avoided h Any other safety recommendations provided or advised by the Vehicle kit manufacturer kit supplier to be complied with Note The instructions issued by OE manufacturer retrofitter for third party evaluation in their instruction manual shall contain all the necessary details on the methodology amp the procedure for carrying out these checks Signature amp Seal with date 38 Annexure X Tests to be carried out by Test Agency Annexure X a Tests to be carried out by Test CNG Fitment by OE Manufacturer for New Vehicle For CNG Fitment by OE Manufacturer for New Vehicle Performance test to be carried out by For converted For OE dedicated For OE Dual Test Agency Gasoline vehicles CNG vehicles fuel CNG vehicles Mass emission test y y Engine performance test y y y Constant speed fuel consumption test y y Ve as applicable Gradeability test NA y y EMI EMC test as notified by NA y y Government of India from Time to time Range test of atleast 250 km for buses NA y y Cooling performance test as per IS NA y
15. relevant Statutory Authority Test Agency shall be used 1 2 1 This Standard is not intended to cover CNG fuel systems for the propulsion of marine craft 1 3 Definitions For the purpose of this Standard the following definitions shall apply APPROVED OR APPROVAL Approved by or approval of the Statutory Authority AUTHORIZED PERSON A person normally an automotive workshop person authorised by the vehicle manufacturer or the conversion kit manufacturer kit supplier specially trained for installation maintenance and periodic inspection of motor vehicle converted for Dual fuel or bi fuel or dedicated operation of internal combustion engined vehicles AUTOMATIC FUEL SHUT OFF VALVE A device such as solenoid valve for shutting off the fuel supply unless certain essential conditions exist COMPRESSED NATURAL GAS CNG A compressed gaseous fuel composed predominantly of methane CH shall be used as specified by the Government of India from time to time CONSTRUCTION EQUIPMENT VEHICLES Means rubber tyred including pneumatic tyre rubber padded or steel drum wheel mounted self propelled excavator loader back compactor roller dumper motor grader mobile crane dozer fork lift truck self loading concrete mixer or any other construction equipment vehicle or combination then designed for off highway operations in mining industrial undertaking irrigation and general construction but modified and manufactured with on or off o
16. safety considerations be compromised 43 2 1 4 Cylinders shall be re tested as per Gas Cylinder Rules 1981 as amended from time to time 2 2 Fittings on cylinders and filling connection 2 2 1 Cylinder valve Each cylinder shall have a manual cylinder shut off valve mounted directly on it capable of shutting off all gas flow from that cylinder Cylinders and shut off valve assemblies shall be approved endorsed by the Department of Explosives as per Gas Cylinder Rules 1981 as amended from time to time 2 2 2 Filling Connection The filling connection shall be of the NZS NGV 1 or any other type as specified by the Government of India from time to time The basic dimensions for NZS type are as given in Appendix D and recommended sizes of NGV 1 type of filling connection are SAE 9 16 and 7 8 However the vehicle manufacturer kit installer may seek the guidance from The Gas Authority of India Ltd Ministry of Petroleum and Natural Gas about the use of specific type of NGV 1 nozzle 2 2 3 The NZS type filling connection shall be provided with a captive dust plug and NGV 1 type filling connection shall be provided with dust protection cap 2 2 4 Position of filling connection The filling connection shall be located in suitably protected and ventilated location usually the engine compartment and shall comply with the following a The filling connection is made and filling is supervised from outside the vehic
17. third party inspection of fully built CNG buses before registration 7 1 2 Periodic Inspection preventive maintenance 7 1 2 1 The cylinder piping and all components of the system shall be examined by an installer for corrosion deterioration and for any modification affecting compliance with this Standard at least once in a year or incase of malfunction or accident The inspection shall include leak testing under 7 2 of this Part of this Standard Every CNG bus manufacturer installer shall incorporate periodic inspection schedules in the operation and owner s manuals 7 1 2 2 When the system has been inspected and any defects remedied and the system conforms to this Standard to the satisfaction of the installer a checklist as per Appendix A in case of buses it shall be as per Annexure VII of AIS 024 of this Standard shall be issued to the owner of the vehicle 60 7 2 Leak testing 7 2 1 Initial test At the time of commissioning the complete pressure system shall be subjected to a pressure test of 20 1 MPa by using CNG or a gas inert to CNG such as nitrogen Procedure a With boot or cylinder compartment open and vapour sealing removed from cylinder valve area and cylinder valve closed slowly pressurize the system WARNING The system must not be subjected to a shock loading as insecure fittings could blow out with dangerous results and burst discs could rupture b Leak test lines fittings and components usin
18. to fit the kit on behalf of manufacturer Kit installer shall be equipped with the following tools and equipment Two post lift ramp Electric hand drill machine and H S S drill bits Tube bender Tube cutter Deburring tool for tube Set of D ring and box spanners Set of screw driver both flat and star Set of allen keys H S S hand saw Crimping tool for electrical cable termination Soap bubble bottle Set letter and number punch Infrared pollution meter Timing gun Filler gauge Measurement tape Air compressor Flame proof inspection light Vernier caliper Multimeter Silicon seal sealant Firefighting equipment Dry chemical powder DCP type Minimum two numbers of 5 kg each with ISI mark CO type fire extinguisher minimum 1 number of 5 kg with ISI mark Fire buckets 2 buckets Installer shall have trained technicians having minimum ITI qualification and at least two years of experience in the similar field Vehicle kit manufacturer supplier to impart extensive training to the technicians on CNG kit installation 10 11 12 13 Annexure V Page 2 3 Installer to display in the premises authorization certificate issued by vehicle manufacturer kit manufacturer supplier Also installer to display details of the facilities available in terms of equipment and trained manpower After obtaining the type approval certification the vehicle kit manufacturer supplier s shall authorize the in
19. to run on a gaseous fuel This includes devices such as fuel provision and control device the ignition system if one is used the speed and or load governing device if any and any engine protection devices such as temperature and pressure alarms and knock detection systems 4 2 Control Equipment 4 2 1 Filter At the termination of every CNG service fuel line immediately prior to any regulator component there shall be fitted a properly designed filter capable of removing all particulate matter from the fuel that could cause malfunction of such regulator components 4 2 2 CNG shut off valve 4 2 2 1 This valve shall shut off fuel supply to the engine when activated by the fuel change over control on dual fuel bi fuel fuel operation and by the ignition switch on single fuel operation Normally this is a regulator component but in any case it shall be located downstream of the filter This valve shall automatically shut off the fuel supply to the engine unless the following conditions are satisfied a The ignition is on b The engine is turning 4 2 2 2 Service shut off valve A service shut off valve shall be installed in the high pressure line between the cylinder valve and any other valve or component within the engine compartment and as close as practicable to the Regulator however it is acceptable to install the valve at the refueling point It shall be possible to readily operate the valve in the installed position at a
20. within it shall not support combustion and shall meet the following minimum criteria i The conduit shall withstand an internal pressure of 30 kPa ii The conduit shall not suffer sufficient damage to permit leakage when tested by applying a 60 kef static force applied through 20 mm diameter in the following manner 1 Applied to a free length of conduit minimum length of 500 mm 2 With the conduit connection clamped up in position the force then applied 5 mm from the end of this coupling so as to place the connection in tension iii Flammability The material shall conform to SAE J 369a class SE NBR iv Presence of resistance to ultraviolet degradation agent shall be confirmed NOTE Item c shall be the basis of approval for proof of design of the conduit 2 4 3 2 Pliable material A sub compartment may be constructed of pliable material attached to the cylinder so that the cylinder valve piping and connections are contained within the sub compartment The pliable material shall meet the requirements of this clause and shall be clearly marked accordingly 48 2 4 3 3 Where the sub compartment is removed to initiate repairs or at the periodic inspection special attention shall be given to the inspection of the material to ensure that no degradation of material has taken place Any sub compartment showing signs of degradation shall be replaced 2 4 3 4 The cylinder valve actuating device position shall be clearly identi
21. 19 25 Annexure VIII to AIS 024 Checklist for preventive maintenance of in use CNG vehicles 26 30 10 Annexure IX to AIS 024 Checklist for third party checking inspection of CNG vehicles other than CNG buses before registration New and In use 31 39 11 Annexure X to AIS 024 Tests to be carried out by Test CNG Fitment 40 41 12 AIS 028 vehicles Code of practice for use of CNG fuel in internal combustion engined 42 81 AIS 024 SAFETY AND PROCEDURAL REQUIREMENTS FOR TYPE APPROVAL OF CNG OPERATED VEHICLES Safety and Procedural Requirements for Type Approval of CNG Operated Vehicles Dedicated Bi fuel amp Dual fuel For CNG Fitment by For Retrofitment of For Replacement of In OE Manufacturer for In Use Vehicle CNG Use Diesel Engine by New Vehicle Dual Fuel Engine New CNG Engine Documents to be Specification of CNG Specification of CNG kit as Specification of CNG kit submitted kit in the given format per Annexure I as per Annexure I as per Annexure I Detailed and brief Technical specification of Technical specifications of technical specifications the retrofitted vehicle as per in use diesel vehicle as per of vehicle in AISC Annexure II Annexure II format AIS 007 Details of alterations Technical specification of carried out on diesel engine vehicle and CNG engine to CNG along with names as per Table 2 and 4 of of th
22. ARAI ress through Researc Finalized Draft AIS 024 SAFETY AND PROCEDURAL REQUIREMENTS FOR TYPE APPROVAL OF CNG OPERATED VEHICLES DEDICATED BI FUEL amp DUAL FUEL And AIS 028 CODE OF PRACTICE FOR USE OF CNG FUEL IN INTERNAL COMBUSTION ENGINED VEHICLES Version 4 Date of hosting on website 3 Dec 2014 Last date for comments 2 Jan 2015 Prepared by The Automotive Research Association of India Post Box No 832 Pune 411 004 CONTENTS Sr No Document Description Page No AIS 024 Safety and procedural requirements for type approval of CNG operated vehicles 3 4 Annexure I to AIS 024 Technical specification of CNG kit 5 8 Annexure IT to AIS 024 Technical specification of vehicles 9 10 Annexure III to AIS 024 Checklist for fitness tests and certification for in use vehicles after fitment conversion to CNG mode 11 Annexure IV to AIS 024 Safety checks for use of CNG fuels in internal combustion engined vehicles as per AIS 028 amp Indian gas cylinder rules 1981 12 13 Annexure V to AIS 024 Criteria to authorize the kit installer and responsibility of vehicle kit manufacturer supplier installer 14 16 Annexure VI to AIS 024 Installation certificate for converted CNG vehicle 17 18 Annexure VII to AIS 024 Checklist for third party checking or inspection of built up CNG buses New and In use before registration
23. Catalytic Converter wherever it is part of kit a Verify make and type of the catalytic converter as per the vehicle manufacturer s specification and as given in the type approval certificate as the case may be 19 Low pressure hose a Verify make and type of the low pressure hose as per the Type Approval specification b Check for kinks damage or abrasion to the cover Note In case of doubt Inspecting Agencies will request the OE vehicle manufacturer retrofitter to supply the sample of material for low pressure hose which has been type approved by the testing agencies 37 20 Following additional points are to be complied at the time of registration before endorsement by the competent authority after conversion of CNG vehicle for enhancement of safety of vehicle a Fire retardant material conforming to FMVSS 302 for seat upholstery roof amp side lining amp IS 2465 for wiring cables shall be used The OE Vehicle manufacturer retrofitter shall submit declaration with respect to design manufacturing processes and material conforming the use of fire retardant materials Notes For OE fully built vehicles type approval is subjected to meeting the requirements as mentioned above In case of type approval of drive away chassis declaration from chassis manufacturer for above tests shall be verified by inspection agency In case of doubt Inspecting Agencies will request the OE vehicle manufacturer retrof
24. Ensure cylinder is securely mounted Weekly within the vehicle check tightness of nuts and bolts e Ensure minimum 5 mm clearance is Weekly kept between cylinders and vehicle body structure e Distance between cylinder valve and se Weekly bus body extremities shall not be less than 200 mm Cylinder Valves a Approval from PESO Periodicity of checks b Check for Shield protection and physical Weekly damage to valves c Leak test using non corrosive foaming agent or Daily Methane leak detector Refilling Valve Periodicity of checks Check for dust cap plug Weekly Check that engine should not start when dust Weekly cap plug is removed or open Check leakage for non return valve using non Dail aily 27 Fuel Line Periodicity of checks Check for corrosion on CNG fuel line Ensure fuel line is securely mounted Check for deformation of U amp pigtail bends Check hose for twists kinks and damage or abrasions to the cover which expose the wire fiber and shall be condemned on detection of any one of these defects During servicing hose shall be replaced by new hose after removal from vehicle Check distance between fuel line and exhaust heat source is more than 75 mm Leak test using non corrosive foaming agent or methane leak detector Weekly Weekly Weekly Weekly Weekly Weekly Daily Shut Off Valve Solenoid Valve s wherever separately provided Periodicity of checks Ensure s
25. For Replacement of In For Retrofitment of OE Manufacturer for In Use Vehicle Use Diesel Engine by New Vehicle New CNG Engine Performance As per Annexure X a As per Annexure X b of As per Annexure X c of Tests as per of AIS 024 AIS 024 AIS 024 CMVR Safety Checks As given in Annexure As given in Annexure IV of As given in Annexure as per AIS 028 IV of AIS 024 AIS 024 IV of AIS 024 Criteria to authorize kit installer and responsibility of the vehicle kit manufacturer supplier installer As given in Annexure V of AIS 024 As given in Annexure V of AIS 024 Format of installation certificate for converted CNG vehicle As per Annexure VI of AIS 024 As per Annexure VI of AIS 024 As per Annexure VI of AIS 024 Checklist for third party checking or inspection of built up CNG buses before registration As per Annexure VII of AIS 024 Checklist for preventive maintenance of in use CNG vehicles As per Annexure VIII of AIS 024 As per Annexure VIII of AIS 024 Annexure I Page 1 4 TECHNICAL SPECIFICATION OF CNG CONVERSION KIT DEDICATED BI FUEL amp DUAL FUEL ER Details of Kit Manufacturer Supplier Installer Name of the Manufacturer Address Telephone No amp Fax No Contact person CNG Kit Identification Identification No Variants if any CNG Cylinder PESO approved endorsed Name of manufacturer Identification N
26. No indicating also revision status Signature Signature Name Name Designation Designation Date Date Sheet No of Annexure II Page 2 2 Frame Long Member Size mm Number of Cross Members Suspension Spring Anti Roll Bar Shock Absorber Brake Service Brake Front Rear Total Braking Area Parking Brake Wheels and Tyres Electrical System System Voltage Battery Alternator Max Output Type Wiper Motor Fuel Tank Dimensions Wheel Base mm Overall Width mm Overall Length mm Front Track mm Rear Track mm Min Ground Clearance mm Cargo Box Dimensions Load Body Platform Area Weights Maximum GVW Maximum Permissible FAW Maximum Permissible RAW KERB weight with 90 fuel with spare wheel tools etc Maximum Gradeability in 1 Gear Seating Capacity Test Agency Manufacturer Document No indicating also revision Signature Signature status Name Name Designation Designation Date Date Sheet No of Annexure IIT Page 1 1 CHECKLIST FOR FITNESS TESTS AND CERTIFICATION FOR IN USE VEHICLES AFTER FITMENT CONVERSION TO CNG MODE DEDICATED BI FUEL amp DUAL FUEL Sr No Description 1 Spark plug Suppression cap HT cables 2 Head lights 3 Other lights 4 Reflectors 5 Bulbs 6 Rear view mirrors 7
27. Service shut off valve Periodicity of checks e Check operation replace in case inoperative Weekly e Ensure service shut off valve is securely mounted Weekly e Leak test using non corrosive foaming agent or methane leak detector Daily 10 CNG Filter Periodicity of checks e Ensure CNG filter is securely mounted Weekly e Leak test using non corrosive foaming agent or I methane leak detector Daily 11 CNG Pressure Gauge Periodicity of checks e Ensure CNG pressure indicator is securely Weekly mounted e Check for operation replace if it is Weekly inoperative Daily e Leak test using non corrosive foaming agent or methane leak detector 29 12 Following additional points need to be complied for carrying out preventive maintenance every month unless and otherwise specified Replace spark plugs and high tension cables as per manufacturer s recommendations Check ignition timing by using timing light at engine idle speed and other speeds as specified and correct if required Check function of O sensor output milli volt variation using multimeter as per manufacturer s recommendations Check for any exhaust gas leak before the catalytic converter and correct if necessary Replace catalytic converter as per manufacturer s recommendations One number each type of dry powder type fire extinguisher 2 kg shall be provided in driver and passenger compartment Buses should be properly maintained and checked
28. TIVE MAINTENANCE OF IN USE CNG DEDICATED DUAL FUEL VEHICLES This checklist is A GUIDE for preventive maintenance of fully built in use CNG vehicles Preventive maintenance shall be carried out by authorized installer at authorized workshop only as prescribed in CMVR Reference to relevant clauses of Safety Code of Practice e g AIS 028 and guidelines issued by Central Government from time to time should be made wherever appropriate testing agency approvals the time of Type Approval A Details of CNG Vehicle 1 Name and address of owner of vehicle 2 a Type of vehicle as per AIS 053 b Model 3 a Name of OE manufacturer b Name of kit retrofitting agency 4 Name and address of bus body builder 5 Name and address of approved inspecting agency at R T O 6 Chassis No Engine No and Vehicle Registration No 7 a Year of manufacture of vehicle b Date of endorsement of CNG kit in RCTC book B Detail of CNG System 1 Checking of Cylinders as per PESO vehicle Approved Specification at Remarks of Inspection Authority d No of Cylinders e Approval from PESO f Validity of PESO Certificate Check or Re test cylinders as per Gas Cylinder Rules 1981 26 Other checks e Check for corrosion on any CNG components mountings of gas Periodicity of checks Weekly corrosive foaming agent or Methane leak detector cylinders e
29. ale QUmO y 28 U02 p 01 JIJyM UOI jo jurod aul anua peoy Figure 1 74 JONVEVSTO ONNOYO ANVI 39YYOLS 1303 TVNISINO 30 NOILISOd TWIldAl Z 913 HAdHNE HO ABOMACOS ONIL ININVH dd YO SISSVHI 30 iNIOd 253401 Vo w NN oN WN OLO Il ANYI Bj TWNI9I8O G 3 LOWEST CHASSIS BODY WORK OF TRAILER TRAILER MOUNTING OF CYLINDERS GROUNO CLEARANCE 76 di CYLINDER CYLINDER CYL SHUT OF CYL SHUT OFF VALVE VALVE EXCESS FLOW f QUICK CONNECT VALVE EXCESS FLOW ie a VALVE mn Be a 2 POINT SHUT OFF VALVE MANUAL VENTING VALVE k ISOLATING 90 ERVICES VALVE ALVE ERVICZ VALVE VALVE 2 alco fuel line pressure VENT rele ace STRUCTURE ATTACH TO F TRAILE 77 AMENDMENT RECORD This document contains AIS 024 and AIS 028 Version 1 Effective from 21 May 2001 Discontinued from 12 July 2001 Version 2 Effective from 12 July 2001 Version 3 Effective from 26 February 2002 Version 4 Effective from Justification for Revision to AIS 024 AIS 024 standard is being amended as per directives received from AISC on account of the following 1 Incorporation of all previous amendments in the main body of the standard from point of view of better readability and user friendliness 2 Incorporation of safety and type approval requirements for dual fuel i e diesel cng vehicles in addition to existing requirements for dedicated and bi fuel CNG operation The addition of specif
30. anufacturer 1 b G Name and address of the Drive Away Chassis Manufacturer applicable for new amp Converted Retrofitted in use 1 b Gi Name of the Retrofitter holding the type approval certificate l c Name of the authorized kit installer duly authorized by the original retrofitter 1 d Name and address of Body builder if applicable 2 Name of type approval agency 3 Reference number of type approval certificate 3 1 Validity 3 1 1 Gasoline Vehicles Converted Retrofitted in use a CC of base model tested b Flexibility available for conversion 25 of the base model c Period of validity i e from to 3 1 2 Diesel Vehicles Converted Retrofitted in use a Type and make of model b Year of manufacture c Period of Validity i e from to 3 1 3 In the case of OE a Validity will be for the base model and its variants given in the type approval certificate b Period from to as given in the type approval certificate 4 Name and address of approved inspecting agency at R T O 5 a Vehicle Registration No if applicable b Vehicle type amp model 6 Chassis and engine No 31 Y lt Original as per RCTC or S New in case of replacement of engine Year of manufacture a Chassis in case of drive away chassis b Fully built up vehicle c Month amp year of conversion B Detail of CNG System 1 Checking of Cyli
31. ast testing and the name of certifying agency c Water capacity Itr d Next due date of testing e Water capacity Itr of total installation f Vehicle registration identification No to be furnished after registration g Seal Identification of the checking inspection agency who carries out the 3 E party inspection h Check whether compliance plate is installed near filling connection be clearly visible to the filling agency 36 13 Identification label in front and rear a Located on left side of the front and rear safety glass and shall ensure visibility from front and rear sides 14 Compartment Sub compartment Gas tight housing for internally mounted cylinder s a Check whether Compartment Sub compartment Gas tight housing is in good condition i e shall not show any crack damage b Check whether it is firmly clamped to the conduit vent hose ducting 15 Conduits ducting vent hose for internally mounted cylinder s a Check whether Conduits ducting is in good condition i e shall not show any crack damage 16 Petrol Shut Off Valve Solenoid if applicable i e Gasoline injection vehicle PESOs not require such solenoid valve a Check operation b Check whether Petrol shut off valve is securely mounted C Leak test visual inspection d Verify the make amp type as per the Type Approval specification 17 Fuel selection switch for bi fuel mode e Check operation 18
32. ay that in one position the flow of gas from the cylinders through the excess flow valve will be permitted while in the other position the fuel line from the cylinders is isolated and the line through the coupling is vented to atmosphere A permanent label shall be provided MANUAL VENTING VALVE in such a way as to clearly indicate the position and function of the valve The manual venting valve is to be operated before the disconnection of the coupling thus releasing pressure from the coupling and fuel line between the check valve in the line of the towing vehicle and the manual venting valve This venting operation is to be conducted in an open well ventilated space at least 15 meters from any naked flames or other source of ignition A plate shall be permanently attached to the fuel line next to the coupling and shall be marked as follows DANGER NO SMOKING PRIOR TO UNCOUPLING RELEASE LINE PRESSURE AT MANUAL VENTING VALVE 54 NOTE The allowable amount of free movement of hose between the towing and towed vehicle shall be such as to minimize whipping of the hose should the hose be severed 4 CNG CONTROL EQUIPMENT 4 1 Definition 4 1 1 The CNG fuel control equipment includes all the equipment necessary to convert CNG at high pressure at the cylinder to CNG air mixer for supply to the engine In case of heavy motor vehicle engine control equipment includes all the equipment used to convert a compression ignition engine
33. be dedicated to the CNG fuel system NOTE Where fuses are used they should be sized to conform such that 110 of rated current of the circuit shall not fuse within 60 minutes and at 135 of the rated current of the circuit it shall fuse within 60 seconds A circuit breaker meeting this criteria is acceptable 4 3 4 Connectors and terminals 4 3 4 1 Connectors and terminals shall be insulated to prevent accidental earthing during operations or routine servicing 4 4 Pressure indicator 58 4 4 1 A pressure indicator to indicate pressure in the CNG gas cylinder shall be fitted in an easily visible position to service personnel at the regulator or fill point preferably within the engine compartment 4 4 2 A supplementary gauge or electronic gauge may be placed in the driver s compartment provided any gauge shall be gas isolated from the cylinder or piping to prevent gas leaking into the compartment 5 COMPLIANCE PLATE 5 1 Compliance plate There shall be installed near the filling connection and be clearly visible to the re fueler a compliance plate displaying the following information COMPLIANCE PLATE CNG Cylinder Identification Number s Date of Installation Water Capacity litre of the Total Installation Date of the Last Retest Vehicle Registration Identification No The CNG installation complies with the safety requirements of AIS 028 Installed by 6 LABELS 6 1 Identification labels 6 1 1 V
34. c Check for U and Pigtail bends provided in high pressure piping for flexibility as per approved layout d Check whether effective protection is provided as per approved layout to prevent the possibility of damage due to loose objects from road e Distance between fuel line and exhaust pipe shield shall not be less than 75 mm and the fuel line should also be properly clamped and routed so as not to touch the engine block Jf Check the distance between any two clips which shall not be more than 600mm 500mm amp 300mm incase of 3 2 wheeler respectively g Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 33 5 Shut Off Valve Solenoid Valve s wherever separately provided e Safety checks Verify the following as per type approval specification gt Make gt Type if applicable gt Identification No Check whether shut off valve is securely mounted Check operation for Close amp Open as required Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 6 Regulator e Safety checks Verify the following as per type approval specification gt Make gt Type if applicable gt Identification No Check whether regulator is securely mounted Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 7 Gas Air Mixer
35. d reverse direction of travel of the vehicle Hose couplings shall be of the failsafe or dry type having internal valves which prevent the loss of fuel when breakaway occurs or when the coupling is undone The fuel line upstream of the breakaway coupling must be protected by an accessible manually operated isolating valve If cylinders are present on a towing vehicle an accessible manually operated isolating valve shall also be fitted on the towing vehicle NOTE The allowable amount of free movement of hose between the towing and towed vehicle shall be such as to minimize whipping of the hose should the hose be severed 3 4 2 High pressure transfer of CNG Refer fig 3 Where high pressure CNG is transferred between the towing and towed vehicle 3 4 1 c d and g shall a b c d e apply along with the following clauses A quick connect coupling shall be provided within the connection of the flexible hose between towed and towing vehicle and the rigid fuel line installed on the towing vehicle For any tractor unit provided with CNG storage cylinders the system shall have installed on the tractor as close as practicable to the coupling a check valve to prevent flow of gas from the cylinders on the tractor through the coupling The system shall have installed on the trailer downstream and as close as possible to the quick connect coupling a manual venting valve having 3 ports The valve shall be fitted in such a w
36. e approved by the testing agencies Rubber packing if found damaged during inspection it should be replaced by the new material having revised specification 32 2 Cylinder Valves a Check specific type amp model approved by Vehicle testing agency for the vehicle under inspection b Check for operation c Check for physical damage distortion to valves d Check for Shield protection e Check for burst disc with fusible plug as approved by PESO Jf Check for the vent pipe outlet routing away from exhaust in case of cylinder fitting in the enclosed compartment g Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 3 Refilling Valve e Safety checks a Check for dust cap plug b Check that engine should not start when dust cap plug is removed or open e Check for proper make amp type of interlocking switch as approved by testing agencies c Check leakage for non return valve using non corrosive foaming agent i e snoop of M s Swagelok collin etc or Methane leak detector 4 Fuel Line e Safety checks a Check for corrosion damage of CNG fuel line 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 CNG fuel line b Check whether fuel line is securely mounted
37. e supplier AIS 007 CMVR Checks CMVR checks tests Undertaking by the kit Undertaking by the vehicle are to be conducted by manufacturer supplier manufacturer kit Test Agency as per regarding fitness as per manufacturer kit supplier CMVR No 93 to 125 Certificates of original petrol diesel engined vehicles to be produced for checking compliance of as many common rules of CMVR for petrol diesel vehicle and CNG vehicle Whichever rules are not complied with because of changes made for conversion the same are to be re checked as per applicable CMVR Annexure III and fitness compliance as per CMVR as amended by the Government of India from time to time of the in use vehicle to be submitted to the test agency for the examination and evaluation before undertaking performance tests on CNG fuelled vehicles Assessment of structural integrity in case of heavy passenger goods diesel vehicles to be provided by the retrofitter or kit installer regarding fitness as per Annexure III and fitness compliance as per CMVR as amended by the Government of India from time to time of the in use vehicle to be submitted to the test agency for the examination and evaluation before undertaking performance test on CNG fuelled vehicles Assessment of structural integrity in case of heavy passenger goods diesel vehicles to be provided by the retrofitter or kit installer For CNG Fitment by
38. ections for use with pressures exceeding 2 15 MPa shall be steel piping for use with CNG shall have a minimum burst test pressure of 70 MPa and effectively protected against corrosion for 24 hours in accordance with ASTM B 117 or equivalent 3 1 2 CNG fuel line and connections for use with pressures exceeding 100 kPa but less than 2 15 MPa shall be tested as per IS 15722 2006 The material of the flexible hose made up of synthetic rubber or composite materials like fiberglass PTFE Teflon and steel braiding shall meet the requirements of SAE J30 R6 R7 R8 or ISO 15500 or equivalent standard except testing on slab 3 1 3 Flexible hose exceeding 2 15 MPa Flexible hose shall meet the following requirements 3 1 3 1 Flexible hose shall meet SAE 100R1 except impulse loading test and testing on slab or equivalent Each flexible hose assembly shall be permanently and clearly marked with the manufacturer s name and trademark type size and design working pressure It shall be identifiable as being suitable for CNG use either by marking it with CNG or with a specification mark 3 1 3 2 Ageing Test When hose is aged for 72 hrs at 125 2 deg C and then tested in accordance with IS 3400 for the tensile strength and elongation at break of the lining and cover shall not vary from the corresponding pre determined unaged values by more than 40 3 1 3 3 Installation 3 1 3 3 1 The hose shall be supplied and fitted as a fully made up a
39. een the fuel pump and the automatic shut off valve in the liquid fuel line to the carburettor on vehicles equipped with bi fuel systems for the use of petrol and gaseous fuel The relief device need not be installed on fuel pumps containing a bypass relief device as original equipment 4 2 5 2 5 Fuel selection control A fuel selection control shall be provided which shall have at least three positions clearly marked for the selection of each of the two fuels The selection control shall be placed within easy reach of the driver or operator For vehicles fitted with electronic fuel injection a two position switch is acceptable 4 2 5 3 For Dual fuel type 4 2 5 3 1 A shut off device shall be installed in the Dual fuel system This device shall shut off the CNG fuel supply to the engine when this is not required 4 2 5 3 2 If the shut off device is in the form of a solenoid operated shut off valve it must be fitted between the tank valve and the carburetor Injector The valve shall be mounted securely so that its weight is not taken on any part of the carburetor Injector or fuel lines 4 2 5 3 3 Where the shut off device is mounted remotely after the regulator flexible hose shall be used of sufficient length to accommodate engine movement In all cases the device shall be mounted in a position reasonably protected from damage in a collision and shall be as far as practicable from high tension electrical equipment 57 4 2 5 3 4 Fu
40. ehicles using a CNG system shall be labeled as follows Dedicated Bi fuel Labels conforming with the specification given in 6 1 1 1 of this Standard shall be affixed in a vertical position as close to the vehicle number plate as practical or on the left side of the front amp rear safety glass and shall ensure visibility from the front and rear sides 6 1 1 1 The label shall be in position at all times shall be in good condition and the shape colouring and lettering shall be easily identifiable 6 1 1 2 Label shall be coloured white and sized 80 mm x 80 mm square Label shall have on them the text CNG in a central position not less than 20 mm high coloured black The label shall have a black border 1 mm wide 5 mm inside the outer edge and running parallel to it The 80 mm dimension is measured from the outer edge Refer Appendix C 1 for drawing 6 1 2 Vehicles using a Dual Fuel CNG system shall be labeled as follows Labels conforming with the specification given in 6 1 2 1 of this Standard shall be affixed in a vertical position as close to the vehicle number plate as practical or on the left side of the front amp rear safety glass and shall ensure visibility from the front and rear sides 59 6 1 2 1 The label shall be in position at all times shall be in good condition and the shape colouring and lettering shall be easily identifiable 6 1 2 2 Label shall be coloured orange and sized 80 mm x 80 mm square Label shall
41. el Dual fuel dedicated fuel Details of CNG Kit e Cylinders a No of Cylinder s b Type of Cylinder s c Cylinder No s d Make e Water Capacity litres f Working Pressure kg cm g Approval reference of PESO h Validity of PESO Certificate Cylinder Valves a Make b Valve No c Working Pressure kg cm d Approval reference of PESO Refilling Valve a Make b Type Fuel Line a High pressure pipe dia ID OD b Low pressure pipe dia ID OD Shut Off Valve Solenoid Valves a Make b Type c Operation Voltage Fuel selection switch a Make b Type Regulator a Make b Type c Sr No Annexure VI Page 2 2 8 Gas Air Mixer Injector a Make b Type Note 1 This certificate shall be filled and provided to vehicle owner for all vehicles converted for CNG operation 2 A copy of this certificate along with checklist as per Appendix A of safety document shall be forwarded to RTO and test agency from where the approval for CNG kit is obtained Signature amp Seal of Installer BEFORE REGISTRATION FOR DEDICATED DUAL FUEL Annexure VII CHECKLIST FOR THIRD PARTY CHECKING INSPECTION OF BUILT UP CNG BUSES NEW AND CONVERTED RETROFITTED IN USE This checklist is for third party inspection of fully buil
42. el line be less than 75 mm j Fuel lines shall not be installed where any part will be permanently hidden from sight or can not be inspected or easily replaced except as provided for in 2 4 3 3 2 CNG fuel line pressure not exceeding 100 kPa low pressure fuel line 3 2 1 All CNG fuel lines for use for service pressure not exceeding 100 kPa low pressure hose shall comply with the following a Such low pressure fuel line shall be of flexible material complying with SAE J30R6 R7 R8 or ISO 15500 or equivalent Low pressure fuel line shall withstand test pressure as per IS 15722 2006 times the maximum pressure likely to be encountered in service and shall comply with 3 1 5 1 a to f inclusive and j b Joints and connections for low pressure fuel lines shall be suitable for use with CNG and capable of sustaining 5 times the maximum pressure likely to be encountered in service and shall comply with 3 1 4 2 and 3 1 4 3 3 3 Flexibility 3 3 1 Low pressure hose shall be of sufficient length to accommodate engine movement 3 3 2 High pressure fuel line shall be installed so as to accommodate any relative movement between chassis body and fuel system components or temperature variations in the fuel line 333 All runs of rigid fuel line piping between any two components shall be installed with a pigtail or U bend to provide this essential flexibility Refer 3 3 2 3 4 Trailers and semi trailers The fuel supply line
43. el selection control A fuel selection control shall be provided which shall have at least two modes Diesel and Dual fuel CNG mode clearly marked for the selection of each of the two fuels The selection control shall be placed within easy reach of the driver or operator 4 2 5 3 5 Fuel Level Indicator A fuel level indicator shall be provided which indicates the level of CNG fuel in the tank The level indicator shall be placed within visible range of the driver or operator 4 2 6 Installation 4 2 6 1 The CNG control equipment shall be a Installed in positions that are accessible for routine inspection maintenance ad adjustment b Mounted securely and reasonably protected from damage in a collision c Remote from the vehicle engine exhaust system or protected therefrom by a metal shield d No closer than is avoidable and practicable to any electrical equipment capable of sparking 4 3 Electrical wiring 4 3 1 All wiring shall be properly installed taped clipped or contained in a loom along its length 4 3 2 Wiring cables shall comply with the requirements of JIS C 3406 or equivalent standard for only conductor resistance test spark and immersion test to withstand voltage The kit supplier kit manufacturer or vehicle manufacturer shall submit test certificate test report complying with above requirements 4 3 3 The electrical circuit shall be provided with a current limiting device This equipment or fuse shall
44. encies 24 16 Following additional points are to be complied at the time of registration before endorsement by the competent authority after conversion of CNG vehicle for enhancement of safety of vehicle a Fire retardant material conforming to FMVSS 302 for seat upholstery roof amp side lining amp IS 2465 for wiring cables shall be used The OE Vehicle manufacturer retrofitter shall submit declaration with respect to design manufacturing processes and material conforming the use of fire retardant materials Notes For OE fully built vehicles type approval is subjected to meeting the requirements as mentioned above In case of type approval of drive away chassis declaration from chassis manufacturer for above tests shall be verified by inspection agency In case of doubt Inspecting Agencies will request the OE vehicle manufacturer retrofitter to supply the sample of material for cables Seat upholstery roof amp side lining which has been type approved by the testing agencies b One number each of dry powder type fire extinguishers 2 kg shall be provided in driver s and passenger s compartment c For servicing of CNG vehicle proper instructions detail operational amp service manual with Dos amp DON Ts shall be provided by chassis manufacturer and body builder retrofitter Vehicle chassis manufacturer retrofitter should devise training module and impart training to drivers and technicians f
45. eparture clearances shall be below planes defined in figure 2 for 4 wheeler and above exceeding 3 5 tonnes GVW NOTE Suspension spring U bolts are not classified as structural components vii In any case the lowest point of the cylinders shall not be lower than a horizontal line taken at the lowest point of the front and rear wheel rims line AB in figure 2 for 4 wheeler and above exceeding 3 5 tonnes GVW c Ramp angle for 4 wheeler below 3 5 tonnes GVW 46 The cylinder s shall not be lower than a point defined by a ramp angle of 17 deg Refer Appendix F for calculation To calculate ramp angle the following measurements shall be taken refer fig 1 i A plane through the centre line point of road contact of the front wheel B sloping upward to contact the lowest structural point of the vehicle midway between the axles A line AB in fig 1 and ii A plane sloping from point A defined in 1 downward to the centre line point of road contact of the foremost rear axle wheel C line AC in Fig 1 d Departure angle for 4 wheeler below 3 5 tonnes GVW i The cylinders shall lie within an area C D in fig 1 11 When calculating departure angle the measurement shall be taken along angular plane tangential to the centre line point of road contact of the rear most axle wheel sloping upward and outward to the extremity of the permanent body work or original equipment bumper bar whichever is the lower e All cleara
46. er the vehicle passenger compartment or driver space 2 3 1 4 The clearance between the cylinder the exhaust shall not be less than 75 mm 2 3 1 5 For Heavy Motor Vehicles Only 2 3 1 5 1 In the case of heavy motor vehicles the number of cylinders likely to be required will be of sufficient weight to affect the legal maximum vehicle weight constraints The effects of the chosen position of the cylinders on the following criteria must be assessed and if necessary a reduction in the allowable payload of the vehicle under study be considered 45 a The original manufacturer s maximum design axle loadings b The maximum allowable axle loadings c The maximum gross vehicle weight and or gross combination weight allowed by the original manufacturer A number of alternative cylinder mounting positions may have to be considered in order to minimize the effects mentioned above The effects of removing or replacing existing diesel fuel tanks on weight distribution of the vehicle should also be taken into account in the above calculations NOTE Vulnerability of cylinders and fittings to damage during loading and unloading of the vehicle or load shift or spillage shall be taken into account 2 3 2 a Cylinder shall not be fitted in any position behind the driver seat seat adjusted to rear most position which will hinder the driver seat adjustment unless specifically approved by the testing agency b Cylinder shall not be fitted
47. est report as per IS 15720 2008 by test agency 12 Safety check for installation Safety checks to be carried out by test Relevant clauses of of CNG system agency as per AIS 028 AIS 028 Certificate issued by accredited testing agency of the country of origin or a report issued by internationally accredited test laboratory may also be accepted NOTE 1 Only the standards as amended from time to time as mentioned above shall be referred for compliance Annexure V Page 1 3 CRITERIA TO AUTHORIZE THE KIT INSTALLER AND RESPONSIBILITY OF VEHICLE MANUFACTURER KIT MANUFACTURER SUPPLIER INSTALLER APPLICABLE TO CNG VEHCILES DEDICATED BI FUEL DUAL FUEL The following are the criteria to be complied by the kit supplier manufacturer for conversion of in use vehicles to operate on CNG fuel 1 The replacement of engine retrofitment of CNG kit shall be type approved by any one of the testing agencies specified in Rule 126 of the Central Motor Vehicle Rules The responsibility of the type approval and ensuring that the kits manufactured comply with the provisions and installation thereof shall be that of the vehicle kit manufacturer supplier as the case may be Only the Installer authorized by vehicle kit manufacturer supplier shall fit the kit on vehicles For this purpose the vehicle kit manufacturer supplier shall issue a certificate of authorization to the Installer concerned duly authorizing them
48. etc or Methane leak detector 4 Fuel Line e Safety checks a Check for corrosion damage on CNG fuel line 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 CNG fuel line b Check whether fuel line is securely mounted c Check for deformation of U and Pigtail bends provided in high pressure piping for flexibility as per approved layout d Distance between fuel line and exhaust pipe shield shall not be less than 75 mm and the fuel line should also be properly clamped and routed so as not to touch the engine block e Check whether effective protection is provided as per approved layout to prevent the possibility of damage due to loose objects from road f Check the distance between any two clips which shall not be more than 600mm g Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 5 Shut Off Valve Solenoid Valve s wherever separately provided e Safety checks a Verify the following as per type approval specification gt Make gt Type if applicable gt Identification No Check whether shut off valve is securely mounted Check operation for Close amp Open as required d Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector oS 21
49. fied and shall have provided adequate material to allow closing of the valve without damage to the sub compartment sealing 2 4 3 5 The pliable sub compartment shall be shielded or installed in a protected location to prevent damage from unsecured objects and abrasion and a The material shall be sufficiently strong to resist mechanical damage preserve venting integrity shall not support combustion and shall meet the following minimum criteria i Resistance to cold cracking The material shall withstand a bend of 180 applied within 0 5 seconds around a 6 mm diameter former at temperature of 35 C without cracking 11 Flammability The material shall conform to SAE J369a class SE NBR 111 Presence of resistance to ultraviolet degradation agent shall be confirmed NOTE Item a shall be the basis of approval for proof of design 2 5 Cylinder s installation For Construction Equipment Vehicles refer clause 9 2 5 1 Attachment to vehicle refer also to 2 5 1 e Cylinders shall be securely attached to the vehicle to prevent slipping rotating and jarring loose in accordance with the following requirements a The method of attachment shall not cause undue stresses or wear in the cylinder shell b The mounting method shall not significantly weaken the vehicle structure and reinforcement shall be added where necessary to ensure compliance with c below An air gap of not less than 5 mm shall be provided between the c
50. fuel OTRAS mp lt ge P Fuel selector switch Name of manufacturer Model No Type 20 Dual fuel actuation mechanism Mechanical Electronic a Brief description of system b Schematic layout c Identification of critical components 21 Brief Description of System Including Dimensional Layout for Cylinder and other kit components installation ventilation details etc 22 Catalytic Converter Make amp Model 23 Refilling valve interlocking switch a Name of manufacturer b Identification No c Type 24 Current limiting Device Fuse a Name of manufacturer b Identification No c Voltage current rating d Type Test Agency Manufacturer Document No indicating also revision status Signature Signature Name Name Designation Designation Date Date Sheet No of Annexure I Page 4 4 25 Pressure Indicator a Name of manufacturer b Identification No c Type 26 Service shut off valve a Name of manufacturer b Identification No c Type 27 Compartment Sub compartment Gas tight housing a Name of manufacturer b Identification No c Type 28 Conduit a Name of manufacturer b Identification No c Inner amp outer diameter d Type 29 Details of Seat Upholstery roof and side lining a Name of manufacturer b Model name Identification No c Type 30 Details of non moisture re
51. g a non corrosive foaming agent and when leak free c Open cylinder valve pressurize cylinder and check for leaks at valve and cylinder neck d When the system is passed leak free seal venting area 7 22 Gas tightness of compartments and sub compartments 7 2 2 1 The compartment and sub compartment shall be tested at the time of commissioning and subsequently at each periodic inspection to ensure that it is gas tight to the vehicle interior by blowing tracer gas into the compartment or sub compartment and testing the surrounding atmosphere for gas leakage with a gas detector Passages between the compartment and outside air e g ventilation provisions or an access hatch or door in the case of a permanently in built compartment should be sealed during testing Any leakage should be rectified and testing repeated T2222 Should the compartment or sub compartment fail the above tests corrective action shall be taken and the tests repeated until they comply with the test requirements NOTE It may be permissible to check such a compartment or sub compartment before installation of the fuel system provided that nothing in the subsequent installation procedure will negate the validity of the test 7 2 3 Where CNG is used for testing the following precautions shall be observed a Testing shall be carried out under adequately vented conditions b Testing shall be carried out at least 5 m from any open flame or other source of igniti
52. ged fuel lines shall not be repaired in all cases they shall be replaced 8 2 3 Welding brazing and the application of heat shall not be carried out on any part of the cylinder subsequent to manufacture 8 2 4 When a vehicle is involved in an accident causing damage to part of all of the CNG fuel system or where any part of the system necessitates removal to allow for the repair of the vehicle the system shall after re assembly or repair be tested in accordance with 7 2 and a checklist as per Appendix A of this standard be issued If applicable the requirements of 8 3 2 shall also be met 8 3 Scrapping 8 3 1 A vehicle which is about to be scrapped shall have its cylinder removed prior to disposal 8 3 2 Where the cylinder has been subjected to impact or fire damage the cylinder shall be inspected and re tested by the owner of the vehicle as per Gas Cylinder Rules 1981 as amended from time to time NOTE There will always be combustible gas in the cylinder until it has been cleared of all traces of flammable vapour or gas 62 9 CONSTRUCTION EQUIPMENT VEHICLES SPECIAL REQUIREMENTS 9 1 General 9 1 1 This section covers the special requirements of Construction Equipment Vehicles 9 1 2 CNG fuel system installation on Construction Equipment Vehicles shall comply with the requirements of this Standard subject to the allowable variation detailed in this section 9 1 3 Clauses of this Standard which are not applicab
53. have on them the text Diesel CNG in a central position not less than 15 mm high coloured black The label shall have a black border 1 mm wide 5 mm inside the outer edge and running parallel to it The 80 mm dimension is measured from the outer edge Refer Appendix C 2 for drawing 7 INSPECTION TESTING AND COMMISSIONING FOR INSTALLER 7 1 Commissioning Prior to initial use an inspection of the CNG system and components shall be carried out by or under the supervision of an Authorized Person Installer who shall also carry out a complete examination to ensure the system complies with all relevant sections of this Standard and any other statutory requirements as specified by the Central Government 7 1 1 Initial inspection and installation certificate The system shall be leak tested as detailed in 7 2 of this Part of this Standard The installation shall be inspected for compliance with this Standard and all components shall be checked for operational performance In the case of dualfuel bi fuel fuel installations the ability for the vehicle to operate on the optional fuel shall also be tested When the system conforms to this standard an installation certificate as per Annexure VI of AIS 024 signed by authorized person installer shall be issued to the owner of the vehicle For CNG buses checklist as per Annexure VIT of AIS 024 shall be duly filled and complied for carrying out third pary inspection This checklist is for
54. hment points to their chassis members and in some cases also prohibit the drilling of additional mounting holes in the chassis members For any proposed chassis modification due consideration must be given to the particular chassis manufacturer s restrictions with respect to welding drilling and sealing of existing holes Advice on these matters can be obtained from the chassis manufacturer 2 5 2 Cylinder manifolding Where more than one cylinders is fitted to a vehicle it is preferable the cylinders be manifolded together in such a way that all can be simultaneously filled from any fill point on the vehicle Each cylinder shall retain its required individual cylinder valve 2 5 3 More than one cylinder Specific design may be required for the mounting attachment Refer also 1 1 4 2 5 4 Cylinder identification markings should be capable of being read when in the installed position 50 2 6 Shielding 2 6 1 Cylinders shall be installed to ensure that valves and connections on cylinders shall be protected to minimize the possibility of damage due to accidental contact with stationary objects or from loose objects thrown up from the road Valves shall be protected to minimize the possibility of damage due to collision overturning or other accident Parts of the vehicle may be used to provide such protection to valves and fittings de CNG FUEL LINE 3 1 CNG fuel line High amp Low pressure fuel line 3 1 1 Rigid piping and conn
55. hut off valve is securely mounted Check operation for Close amp Open as required and replace if found damaged Leak test using non corrosive foaming agent or methane leak detector Weekly Weekly Daily Regulator Periodicity of checks Ensure regulator is securely mounted Check for shield or protection Replace regulator diaphragms hot water hoses seals in accordance with manufacturer s recommendation Leak test using non corrosive foaming agent or methane leak detector Weekly Weekly Weekly Daily Gas Air Mixer Periodicity of checks Ensure gas air mixer is securely mounted Leak test using non corrosive foaming agent or methane leak detector Weekly Daily Electrical wiring Ensure that current limiting device fuse is fitted as per manufacturer s specs and make Check any loose or open or broken wiring harness in engine compartment under chassis and driver s cabin and take corrective action Cable harness has to be as recommended approved by the OE vehicle manufacturers retrofitters Battery terminal has to have a positive locking Periodicity of checks Weekly Monthly Monthly Monthly 28 Check operation of battery cut off switch as per manufacturer s recommendations Monthly e Check for proper tight fitness and clamping of terminal fitting Replace high tension cables as per manufacturer s recommendation Monthly 9
56. ic clauses for dual fuel technology will enable the safety certification of dual fuel vehicles after CMVR notification References have been taken from dual fuel amendments in ECE R 115 This revision of the standard will help in addressing the new emerging technology of sual fuel and also increase the use of this standard 78
57. ies such as MORTH Test Agencies Transport Authorities as and when demanded The vehicle owner shall apply to the concerned registering authority within 14 days of undertaking the alteration as required under Section 52 of Motor Vehicle Act 1988 for endorsement of particular alteration in registration certificate mentioning place and date of installation and installation certificate number This shall also be ensured by the kit installer The vehicle kit manufacturer or supplier shall impart training to installer on installation maintenance and operation of CNG system and issue the training certificate to installer after completion of training The test agency may devise the appropriate training programme as required 14 15 Annexure V Page 3 3 The training shall encompass the following 13 1 CNG Tank a Fitments on tank b Location and ventilation of tanks c Construction of compartment and sub compartment d Installation of tank e Shielding 13 2 CNG Fuel Line a Testing of CNG fuel line b Flexibility c Installation 13 3 CNG Control Equipment a Installation of regulator and its functioning b Installation of fuel selection switch and its information 13 4 Inspection Testing and Commissioning of CNG System a Commissioning b Leak testing 135 Garaging and Repair a Repair operation of CNG vehicles b Scrapping 13 6 Periodic inspection 13 7 CNG Characteristics and Safety Aspects for Handling and Storage
58. in the engine compartment to be in accordance with Vehicle chassis manufacturer s layout specifications approval Check wiring harness in cabin and passenger compartment to be as per vehicle chassis manufacturer s guidelines approval Cable harness has to be as per the recommendations of OE chassis vehicle manufacturers FOR CONVERTED RETROFITTED IN USE VEHICLES Check wiring harness layout under the floor cabin and passenger compartment for proper sleeving and routing in order to avoid accidental sparking Sc S e Service shut off valve e Safety checks Make amp type Check operation Check whether service shut off valve is securely mounted Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 35 10 a CNG Filter wherever separately provided Check whether CNG filter is securely mounted b Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 11 CNG Pressure Gauge a Make amp type b Check whether CNG pressure indicator is securely mounted c Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 12 Compliance Plate e Installation Check Details for no of Cylinders Check for following 1 2 3 4 Wires a Cylinder identification No b Date of l
59. ipment Vehicles shall not be damaged by the temperatures attained during normal operation under the conditions of maximum rated load and under conditions of maximum overload maintained for a short period of time The maximum temperature rise on the surface of any combustible material of electrical insulation shall not exceed 150 C 9 4 2 The test period shall be that required to establish equilibrium conditions for temperature rise and pressure determinations but shall be continued for not less than 2 hours except that a tractor shall be operated an additional 1 minute period against a bumping post or other obstruction thereby causing the wheels to slip and the tractor to exert maximum draw bar pull in effect During this additional 1minute period the rise in surface temperatures shall not exceed the limits specified 64 APPENDIX A CHECKLIST FOR INSTALLATION DEDICATED BIFUEL DUALFUEL Al This checklist is a guide for the installer when carrying out the inspection prior to issuing installation Certificate Reference to relevant clauses in this Standard and guidelines issued by Central Government from time to time should be made where appropriate a Cylinder Approved by PESO Validity of Certificate Free from corrosion Mounted securely and inside vehicle parameter Mounting points free from corrosion and fractures Shielded and valves protected where necessary 5 mm clearance between cylinder to vehicle components provided Ground clea
60. itter to supply the sample of material for cables Seat upholstery roof amp side lining which has been type approved by the testing agencies b G One number each of dry chemical powder type CO type fire extinguisher 1kg for 4 wheeler LCV etc only shall be provided in driver s and passenger s compartment 11 One number of dry chemical powder type CO type fire extinguisher of 1 kg shall be provided in L7 3 wheeled and M1 category of vehicles such that it shall be easily accessible to all the occupants c For servicing of CNG vehicle proper instructions detailed operational amp service manual with Dos amp DON Ts shall be provided by kit vehicle manufacturer s Vehicle kit manufacturer kit supplier should devise training module and impart training to drivers and technicians for safe operation of CNG system d Check for First Aid kit as per CMVR e Safety plates shield below the pipe joints shall be welded and proper inspection windows shall be provided near the cylinder joints f Minimum one copy of safety instructions shall be displayed in passenger s compartment g Check the following for the vehicles other than M1 category fitted with multi CNG cylinders not incorporating the independent venting system Check for proper venting provided by louvers holes mesh on the side skirt so that in case of any leakage the entrapped gas under the floor escapes to the atmosphere The Vehicle kit manufacturer
61. k detector 12 Compliance Plate 12 1 Installation Check Details for no of Cylinders Check for following 1 2 3 4 a Cylinder identification No b Date of last testing and the name of certifying agency c Water capacity Itr d Next due date of testing Date of Installation Jf Water capacity Itr of total installation Vehicle registration identification No to be Jurnished after registration h Seal ldentification of the checking inspection agency who carries out the 3 party inspection i Check whether compliance plate is installed near filling connection amp be clearly visible to the filling agency 13 Identification label in front and rear a Located on left side of the front and rear safety glass and shall ensure visibility from front and rear sides 14 Catalytic Convertor wherever it is part of kit a Verify make and type of the catalytic converter as per the vehicle manufacturer s specification and as given in the type approval certificate as the case may be 15 Low pressure hose a Verify make and type of the low pressure hose as per the Type Approval specification b Check for kinks damage or abrasion to the cover Note In case of doubt Inspecting Agencies will request the OE vehicle manufacturer retrofitter to supply the sample of material for low pressure hose which has been type approved by the testing ag
62. le The filling connection may be made only if the method of access to it from outside PESOs not result in the opening of a vapour path to the interior of the vehicle thereby negating the effectiveness of a compartment or sub compartment b The filling connection is protected by being located in a recess below the surface of a body panel or by being located so that equivalent protection is provided by the construction of the vehicle c The filling connection shall be attached to motor vehicle in such a manner as to resist without permanent deformation of the mounting attachment a proof load of 50 kgf applied in the forward and reverse directions of travel of the vehicle The proof load shall be applied by full engagement of the filling connection and shall be representative of attempted movement of the vehicle while refueling d The filling operation can be carried out without requiring the operator to lie or crawl under the vehicle or be otherwise subjected to inconvenience discomfort or hazard 2 2 5 Refueling Interlock Device Filling connections in motor vehicles shall be fitted with a system that prevents the engine starting when the dust plug or dust protection cap is removed This system shall isolate the starting device of the vehicle Any other system that isolates the engine starting shall be considered 44 2 2 6 Non return valve There shall be a non return valve fitted on the refueling line to prevent the return fl
63. le to Construction Equipment Vehicles and which are not clearly identifiable as such are as follows Clause 2 3 Location and ventilation of cylinders Clause 2 4 Construction of compartments and sub compartments for internally mounted cylinders refer clauses 2 4 1 and 2 4 2 Clause 2 5 Cylinder installation Clause 3 1 5 Securing and location except paragraphs a to f inclusive and j 9 2 Cylinders and fittings location and mounting 9 2 1 Location 9 2 1 1 A fuel cylinder shall be so located as to minimize the possibility of damage to the cylinder or its fittings and it shall not be located so that it adversely affects driving characteristics of the Construction Equipment Vehicles 9 2 1 2 A cylinder shall not be fitted in any internal location when a suitable external location is available 9 2 1 3 A cylinder and its fittings shall not extend beyond the plan form of the vehicle 9 2 2 Clearance A fuel cylinder shall be installed with as much ground clearance as is practicable but never less than the minimum ground clearance of the vehicle in the vicinity of the cylinder This minimum clearance shall be measured to the bottom of the cylinder or the lowest cylinder fitting 9 2 3 Protection Valves and connections on cylinders shall be protected to minimize the possibility of damage due to accidental contact with stationary objects or from loose objects thrown up from the road Valves shall be protected to minimize the po
64. le to install equipment shall be carried out in accordance with sound engineering practices and in compliance with Central Motor Vehicles Act 1988 and Central Motor Vehicles Rule 1989 and their superseding amendment and notification issued thereafter The following aspects shall be taken into consideration during alteration or modification Where modifications are made to a Suspension mounting locations geometry ground clearance adjustment axles and sub axles or steering mechanism b Original fuel storage the fuel tank assembly fuel tank mounting venting or filler assemblies NOTE In some instances the fuel tank constitutes a structural member of the vehicle c Vehicle structure Holes greater than 13 mm shall not be located within 40 mm of the edge of a panel welded joint or direct load bearing point such as a belt anchor The only holes permitted greater than 13 mm diameter are of the installation of the filling valve or for venting purposes d Braking system including the hand brake and components In this aspect design guidelines supplied by vehicle manufacturers vehicle safety standards of Indian or relevant standard wherever applicable shall be referred NOTE In case of the retrofitment where modification types a b c and d are carried out to heavy motor vehicles these will require prior design approval from vehicle manufacturer 41 1 2 Approved equipment Only equipment and systems approved by the
65. ll times in particular during the refueling operation A permanent label shall be provided CNG service shut off valve or similar wording to positively indicate its purpose and a positive indication of Closed and Open positions of the valve shall be clearly marked 4 2 3 Regulator system 55 4 2 3 1 The regulator system shall not permit gas to pass after the engine has stopped turning irrespective of whether the ignition is on or off The regulator shall be installed so that a It is securely mounted as far as practical from the extremities of the vehicle b It is mounted securely and as close to the engine carburettor position as convenient c It is easily accessible for routine maintenance adjustment and inspection d It is situated as far from the exhaust system as practical Where this distance is less than 150 mm it shall be shielded from radiant heat and any impingement from exhaust gases due to exhaust system failure e It is reasonably protected from impact in a collision f It allows sufficient free movement of all hoses g The water circulating system where required is connected in accordance with the manufacturer s instructions and no flow control valve in the system can shut off original equipment water flow h Where possible the regulator should be at lower level than top of the radiator as insufficient water may cause freezing Refer also Appendix E for precautions against freezing
66. mize the possibility of damage due to collision overturning other accident Check that the material of the padding lining provided for inner side of cylinder mounting band s is made up of EPDM non moisture retaining rubber hardness Shore A 60 min and tested as per AIS 066 as approved by the test agency during type approval certification Note In case of doubt Inspecting Agencies will request the OE vehicle manufacturer retrofitter to supply the sample of material for padding rubber which has been type approved by the testing agencies Rubber packing iffound damaged during inspection it should be replaced by the new material having revised specification Cylinder Valves Check specific type model approved by Vehicle testing agency for the vehicle under inspection b Check for operation c Check for Shield protection d Check for physical damage to valves e Check for burst disc with fusible plug as approved by PESO Jf Leak test using non corrosive foaming agent e g snoop of M s Swagelok collin etc or Methane leak detector 20 3 Refilling Valve e Safety checks a Check for dust cap plug b Check that engine should not start when dust cap plug is removed or open e Check for proper make amp type of interlocking switch as approved by testing agencies e Check leakage for non return valve using non corrosive foaming agent 1 e snoop of M s Swagelok collin
67. mp or Lubrication System if any a Name of manufacturer b Type 11 High Pressure Tubing a Name of manufacturer b Model name Identification No c Type d Working pressure kg cm MPa e Max test pressure kg cm MPa f Outer diameter Inner Diameter g Protection quality material used 12 Low Pressure Tubing a Name of manufacturer b Model name Identification No c Type d Working pressure kg cm MPa e Max test pressure kg cm MPa f Outer diameter Inner Diameter g Protection quality material used 13 Gas Air Mixer a Name of manufacturer b Model name Identification No c Type amp drawing d Venturi Size 14 Gas Injector a Name of manufacturer b Model name Identification No c Type amp drawing d Injector flow specs 15 ON OFF Switch a Name of manufacturer b Model name Identification No c Type Test Agency Manufacturer Document No indicating also revision status Signature Signature Name Name Designation Designation Date Date Sheet No of Annexure I Page 3 4 16 Ignition System amp Wiring Harness for CNG system Ref Clause A11 of Table 2 of AIS 007 Name of manufacturer Type of Ignition System Spark plug gap mm Electrical circuit diagram Detail layout Interfacing Unit Name of manufacturer Model name Identification No Type Ignition Timing Advancer Name of manufacturer Type Timing on CNG mode Timing on baseline
68. n Test agency to verify as per AIS 028 Clause no 2 3 2 5 vehicle and 2 6 of AIS 028 2 Cylinder valves PESO Nagpur to certify or endorse in IS 3224 or Gas case of foreign make cylinder rules2004 3 Regulator Testing of the component as per IS 15713 2006 or 1S 15713 2006 or ISO 15500 by test ISO 15500 agency Alternatively test agency to verify the test certificate or report conforming to the above standard issued by accredited testing laboratory 4 Gas Air Mixer Testing of the component as per IS 15714 2006 or 15 15714 2006 or ISO 15500 by test ISO 15500 agency Alternatively test agency to verify the test certificate or report conforming to the above standard issued by accredited testing laboratory 5 Gas Injector Testing of the component as per ISO ISO 15500 7 15500 7 by test agency Alternatively test agency to verify the test certificate or report conforming to the above standard issued by accredited testing laboratory 6 Petrol Solenoid Valve Testing of the component as per IS IS 15717 2006 15717 2006 by test agency Alternatively test agency to verify the test certificate or report conforming to the above standard issued by accredited testing laboratory 6 1 Gas Solenoid Valve Testing of the component as per IS IS 15712 2006 or 15712 2006 or ISO 15500 by test ISO 15500 agency Alternatively test agency to verify the test certificate or report conforming to the above standard issued by accredited testing lab
69. nces shall be measured to the bottom of the cylinder or to the lowest fitting support or attachment on the cylinder or cylinder housing whichever is lowest 2 3 4 Internal cylinders Where a cylinder is located within the body shell of a vehicle either a The whole body of the cylinder together with its attached components and fittings shall be enclosed in a compartment or b The valves and pipe connections associated with or attached to the cylinder shall be enclosed in a localized sub compartment which is attached to the cylinder and vented to the atmosphere Provision shall be made for ready access to the cylinder valve in all installation arrangements NOTE The luggage boot of a car is not considered to be acceptable as a cylinder compartment under a above because of difficulties concerning effectiveness of sealing the maintenance of ventilation openings and the presence of electrical equipment in most boots 2 4 Construction of compartments and sub compartments 2 4 1 A cylinder compartment or sub compartment shall comply with the following requirements a Construction shall be such that any gas which might leak from any fittings component or piping can not pass to any other enclosed compartment passenger space or luggage space of the vehicle b When a sub compartment has been subjected to hydrostatic internal pressure of 30 kPa applied for 5 min sealing materials or gaskets shall not be displaced or otherwise lose
70. nders as per PESO vehicle testing agency approvals Validity of PESO Certificate Safety checks a Check for corrosion on any CNG components mountings of gas circuit Check whether cylinder is securely mounted within the vehicle and check tightness of nuts and bolts Check whether minimum 5 mm clearance is kept between cylinder and vehicle body structure and also in between the cylinders if applicable Distance between cylinder valve and vehicle body extremities shall not be less 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 Check for reinforcement if cylinder is mounted on floor of the vehicle minimum dimension of reinforcement thickness amp surface area shall not be less than 2 5 mm amp 3600 mm respectively The reinforcement shall be provided on the top amp bottom of the floor Check that the material of the padding lining provided for inner side of cylinder mounting band s is made up of EPDM non moisture retaining rubber hardness Shore A 60 min and tested as per AIS 066 as approved by the test agency during type approval certification Notes In case of doubt Inspecting Agencies will request the OE vehicle manufacturer retrofitter to supply the sample of material for padding rubber which has been typ
71. nnections secure Terminals insulated to prevent shorting Wiring taped and clipped securely Compliance Plate Installed and carries correct markings Identification labels Located front and rear of vehicle 66 APPENDIX B STATUTORY AUTHORITY APPROVAL Bl The type of component in question and its use determine the Statutory Authority Approval in respect of CNG Dedicated Bi fuel Dual fuel fuel system components The Statutory areas of responsibility are Government Agency Statutory powers Scope of application B 1 1 Central Motor Vehicle Act 1988 All CNG kit components Ministry of Road Transport CMVA excluding CNG cylinder amp its and Highways Government of India Central Motor Vehicle Rules 1989 CMVR as amended by government of India from time to time valve s and systems used for the purpose of propelling a motor vehicle on road B 1 2 PESO Nagpur Government of India Gas Cylinder Rules 2004 as amended by government of India from time to time CNG cylinder with valves and their accessories 67 APPENDIX C LABEL 68 APPENDIX C 2 LABEL 69 APPENDIX D FILLING CONNECTION AND DUST PLUG 25 gu 10 39 CLERANCE TO FIT OVER PROBE TO SUIT RING SPECIFICATIONS KNAANAS FELLING CONNECTION FEMALE FITTING ON VEHICLE NOTE REFUELLING PROBE IS 10mm DETAIL A GROVE SHORTER THAN THIS FOR D RINGS Sa MFER TO N
72. o Type Working pressure kg cm MPa Max test pressure kg cm MPa Cylinder capacity water equivalent Approval reference from PESO Cylinder Valve s PESO approved endorsed Name of manufacturer Model name Identification No Type Working pressure kg cm MPa Max test pressure kg cm MPa Approval reference from PESO CNG Solenoid Valve Name of manufacturer Model Name Identification No Type Working pressure kg cm MPa Max test pressure kg cm MPa Petrol Solenoid Valve Name of manufacturer Model Name Identification No Type Working pressure kg cm MPa Max test pressure kg cm MPa Refilling valve Name of the manufacturer Model name Identification No Type Working pressure kg cm MPa Max test pressure kg cm MPa EA EA mo ES mo poop E ES Test Agency Manufacturer Document No indicating also revision status Signature Signature Name Name Designation Designation Date Date Sheet No of Annexure I Page 2 4 8 Pressure Regulator a Name of manufacturer b Model name Identification No c Type d Inlet pressure kg cm MPa e Outlet pressure kg cm MPa f No of stages 9 CNG Filter a Name of manufacturer b Model name Identification No c Type d Inlet pressure kg cm MPa e Outlet pressure kg cm MPa 10 Oil Pu
73. o the marked full level line of the bowl Paper is to be placed beneath the intake orifices of an oil bath type and over adjacent surfaces of parts likely to be affected by accumulations of oil The engine is then to be operated in the several manners determined in the preliminary test to provide for the most severe backfire conditions At least ten and not more than twenty backfires are to be produced Observations for containment of flame are to be made under semi darkened conditions by at least two observers No visible flame is to be in evidence at any time during the tests In the tests of an oil bath type paper is not to show evidence of oil deposits in the form of droplets A dry type filter element is to be tested in the above manner then removed and then subjected to five consecutive washing and drying cycles Washing is to consist of immersion in plain water together with sufficient agitation to remove bulk material adhering to the outside surface The test element is then to be remounted as intended in operation and the backfire test is to be repeated The side of the filter media normally exposed to backfire is then to be subjected to a flame source of sufficient intensity to cause the media to burn or glow The flame source is then to be removed and an acceptable filter media is not to continue to burn or smolder 73 JOB UOD peo4 Jaaym Jea jo JUIOd aul a4qUa Line of lowest structural member of chassisibody se
74. ommendations layout g Check for proper make of high tension cable as per chassis manufacturer s recommendation as well as check for tight fitment of its terminal to the spark plug 8 2 FOR OE VEHICLES a Check wiring harness layout under the floor and in the engine compartment to be in accordance with chassis manufacturer s layout specifications approval b Check wiring harness in cabin and passenger compartment to be as per chassis manufacturer s guidelines approval c Cable harness has to be as per the recommendations of OE chassis vehicle manufacturers 8 3 FOR CONVERTED RETROFITTED IN USE VEHICLES a Check wiring harness layout under the floor cabin and passenger compartment for proper sleeving and routing in order to avoid accidental sparking 9 Service shut off valve Safety checks a Make amp type b Check operation c Check whether service shut off valve is securely mounted d Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 10 CNG Filter Check whether CNG filter is securely mounted Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane leak detector 11 CNG Pressure Gauge a Make amp type 23 b Check whether CNG pressure indicator is securely mounted c Leak test using non corrosive foaming agent i e snoop of M s Swagelok collin etc or methane lea
75. on 7 2 4 The operation of the equipment and controls shall also be tested with CNG under normal working conditions to prove satisfactory performance of the entire system and a further leak test shall be carried out using a non corrosive foaming agent 7 2 5 A BCF fire extinguisher and dry powder fire extinguisher to meet IS 2171 and each of 2 kg shall be kept ready within a safe distance If ignition occurs the service valve should be closed and the extinguisher s used to quell any fire which may continue 61 8 GARAGING AND REPAIR FOR INSTALLER 8 1 Garaging and repairing of CNG fueled vehicles 8 1 1 Vehicles fueled with CNG may be stored or serviced and repaired inside garages provided that the following conditions are observed a There shall be no leaks in the fuel system b Such vehicles shall not be parked within 3 m of any sources of ignition c CNG fueled vehicles being repaired in garages unless the fuel is required for engine operation shall have the cylinder shut off valve closed and the CNG fuel in the service line exhausted by running the engine or depressurizing the line in a well ventilated area d Vehicles undergoing repairs involving welding or the application of heat to any part within 1 m of the cylinder shall have the cylinder removed or shielded from the source of heat 8 2 Repair Operation 8 2 1 Repair operation involving heat shall be carried out with due regard to fire safety 8 2 2 Dama
76. or safe operation of CNG system d Check for First Aid kit as per CMVR e Distance between the exhaust line muffler and fuel line shall be a minimum of 75 mm If not a radiant heat shield of 2mm thickness shall be welded inbetween f Safety plates shield below the pipe joints shall be welded and proper inspection windows shall be provided near the cylinder joints g Minimum two copies of safety instructions shall be displayed in passenger s compartment h Check for proper venting provided by louvers holes mesh on the side skirt so that in case of any leakage the entrapped gas under the floor escapes to the atmosphere 1 The bus body builder retrofitter to provide at least two total minimum area of 450 sq mm vent pipes connecting the under floor of the bus to the rooftop for CNG gas to vent out in case of leakage The vent pipes to be located close to the cylinder valves cluster as per recommendations of chassis manufacturer Construction should be such that leakage into passenger compartment is avoided j Any other safety recommendations provided or advised by the chassis manufacturers to be complied with 17 Note The instructions issued by OE manufacturer retrofitter for third party evaluation in their instruction manual shall contain all the necessary details on the methodology amp the procedure for carrying out these checks Signature amp Seal with date 25 Annexure VIII CHECKLIST FOR PREVEN
77. oratory 7 Filling Connection Installation on vehicle to be checkedby Clauses 2 2 2 2 2 3 NZS amp NGV 1 type test agency as per AIS 028 2 2 4 2 2 5 and 2 2 6 of AIS 028 Annexure IV Page 2 2 SAFETY CHECKS FOR USE OF CNG FUELS IN INTERNAL COMBUSTION ENGINED VEHICLES AS PER AIS 028 amp INDIAN GAS CYLINDER RULES 2004 as amended from time to time Sr CNG Kit Component Certifying Verifying Authority Clause of AIS 028 No Other Rules Standards etc 8 Ventilation Test agency to verify eer PIROTA 9 Testing of Conduit Testing of the component or IS 15715 2008 verification of certificate or test report as per IS 15715 2008 by test agency 10 CNG fuel line 10 1 High pressure exceeding 100 kPa 10 1 1 Exceeding 2 15 MPa Rigid pipe Testing of the component or IS 15716 2006 verification of certificate or test report as per IS 15716 2006 by test agency Flexible hose Testing of the component or IS 15718 2006 verification of certificate or test report as per IS 15718 2006 by test agency 10 1 2 Pressure upto 2 15 Mpa Testing of the component or IS 15722 2006 with verification of certificate or test report amendments as per IS 15722 2006 by test agency 10 2 Joints and connections Testing by test agency Clause 3 1 4 1 3 2 1 b of AIS 028 11 Compartment or Sub Testing of the component or IS 15720 2008 compartment verification of certificate or t
78. ow of gas from the cylinder to the filling connection The non return valve shall be located as close to the filling connection as it is practicable 2 2 7 Excess flow valve A device may be fitted in the fuel line preferably at the outlet of the cylinder valve which prevents the total contents of the cylinder from discharging to atmosphere in the event of rupture to any part of the fuel line or components 2 2 8 Diesel Fuel cut off A device mechanism to be provided in the Dual fuel system for cutting of the diesel supply while filling CNG fuel in the vehicle 2 3 Location Ventilation and Mounting of Cylinders 2 3 1 Cylinders Fittings and Pipe work 2 3 1 1 Cylinder shall be mounted in a protected location inside the perimeter of the vehicle Cylinders shall not be located so that the vehicle driving characteristics are adversely affected 2 3 1 2 For externally mounted cylinders In no case shall cylinder valves be positioned less than 200 mm from the extremities of the vehicle unless they are protected to minimize the possibility of damage due to collision overturning or other accident Where the operation of the vehicle is such that the cylinder will be subjected to impact damage from loose metal or other objects being thrown up from the road effective shielding against these shall be provided 2 3 1 3 The cylinder shall be situated and vented so that any gas escaping due to leakage from the cylinder valve shall not ent
79. pse of that section under load iv Anchorage bolts or studs shall have a diameter not less than that shown in table 1 and shall conform to strength grade 8 8 IS 1364 or equivalent ISO 4014 with nuts to 15 1364 or ISO 4032 v Where clamping bands are used at least two steel bands per cylinder shall be provided the dimensions of which shall not be less than those in table 1 To prevent possibility of external corrosion where clamping bands are used a non moisture retaining hard rubber or equivalent material shall be provided on the inner side of the bands Similar adequate protection to the cylinder shall also be provided wherever the cylinder rests against other metal objects such as the mounting frame vi Where the attachment is by means of clamping bands there shall be a positive means of resisting end loads on the cylinder by means of providing suitable end stoppers Except for transverse mounted cylinders vii Screwed fasteners or clamping devices shall either be inherently resistant to loosening or be locked or pinned after tightening e The chassis of heavy motor vehicles can be subjected to considerable torsional and bending deflections even under normal operating conditions Mounting of cylinders to chassis rails must take these deflections into account and the cylinder mounting method chosen must not unduly prevent these deflections occurring In addition many chassis manufacturers specifically prohibit the welding of attac
80. r on and off highway capabilities CYLINDER A pressure vessel for storage of CNG for use as fuel for an internal combustion engine approved endorsed by Department of Explosives under Gas Cylinder Rules 1981 as amended from time to time CYLINDER VALVE A manually controlled shut off valve fitted on the cylinder which can open or shut off the CNG supply and which incorporates a burst disc backed with a fusible material approved endorsed by Department of Explosives under Gas Cylinder Rules 1981 as amended from time to time DEDICATED ENGINE for diesel engine conversion only An engine operating on gaseous fuel only DOWNSTREAM Is the direction in which the stream flows EXCESS FLOW VALVE A valve normally in the open position which closes automatically in the direction of flow for which it is designed when a predetermined flow limit is exceeded EXCESS PRESSURE DEVICE An automatic pressure relieving device GAS AIR MIXER A device for introducing gaseous fuel to the induction air of the engine HEAVY MOTOR VEHICLE A vehicle for either goods or passenger services as defined under the Central Motor Vehicle Rules CMVR as applicable 42 NON RETURN VALVE A valve which permits fuel flow in one direction only PRESSURE Pressure refers to gauge pressure PRESSURE INDICATOR A device to indicate the pressure of gas in the cylinder REGULATOR A device which reduces fuel pressure to a level appropriate for the delivery to
81. rance correct b Valves Cylinder valve operating correctly Burst disc fitted c Filling connection Refueling connection made external to vehicle interior Captive dust plug fitted Meets proof loading of 50 kgf d Refueling interlock Operation correct e Non return valve Operation correct free from bypass leakage f Leak test All valves and fittings leak free g Vapour sealing Gas tight h Ducting Free from damage and secure to outlets 1 Pliable sub compartment Ease of operation of cylinder valve satisfactory Position identified j Fuel line Free from damage and corrosion Secured to vehicle Protected and shielded where necessary k Joints and connections Leak free 1 CNG shut off valve solenoid valve Mounting secure Operation correct Leak free m Service shut off valve Operation satisfactory Mounted securely Leak free Identified and operation clearly marked n Regulator Mounting secure 65 0 p q 1 s t No gas bypass after engine has stopped turning Shielded where necessary Leak free Control equipment Approved type Gas air mixer Securely mounted Backfire deflector where applicable Bi fuel shut off device Operation correct Petrol lock off where fitted is mounted securely Petrol hose secure Joints leak free and free from cracks Sufficient flexibility for engine movement Bypass device fitted where applicable Electrical wiring Current limiting device fitted Co
82. routing is the only possible practicable method of installation the fuel line must be positioned along the lower corner of the tunnel with the underside of the fuel line not more than 15 mm above the intersection with the floor pan The fuel line should follow this route for the shortest distance possible The fuel line shall have a minimum clearance of 40 mm with the drive shaft under all operating conditions This method is not applicable to vehicles where the open axle shaft passes through a tunnel e Use of the wheel arch for fuel line location is not desirable or recommended f Fuel lines shall follow the shortest practical route taking into account the requirements of 3 3 2 g Rigid fuel lines shall be effectively secured to the chassis frame or vehicle body by clips spaced not more than 300 mm apart for 2 and 3 wheeler and 600 mm apart for other vehicles In order to prevent the possibility of fretting corrosion or erosion of the fuel line cushioning must be provided to protect the fuel line from both the chassis body and the clips themselves Suitable grommets must be provided where the fuel line passes through any body panel h Manifolds used in multi cylinder applications shall be installed in a protected location Manifold branch pipelines shall be sufficiently flexible to prevent damage to the lines valves and fittings due to vibration expansion or contraction 1 In no case shall the clearance between the exhaust system and the fu
83. s intrinsically safe NOTE Items b c and d are intended to be the basis of approval for proof of design 2 4 2 Ventilation One or more vents to the outside of the vehicle shall be provided the aggregate area of which is not less than 550 mm for vehicles other than 2 amp 3 wheeler and 250 mm2 for 2 amp 3 wheelers The vents shall be so located as to exhaust any gas which may accumulate in the compartment or sub compartment to atmosphere and shall exit not less than 75 mm from an exhaust pipe or other heat source Refer also to 2 4 3 c Holes for venting shall be positioned not less than 40 mm from the edge of a panel or a welded joint or direct load bearing point refer also to 1 1 4 c 2 4 3 Ducting 2 4 3 1 All piping or hoses that pass through an enclosed area of the vehicle shall be within a conduit gas tight from the vehicle interior vented unobstructed to outside atmosphere and protected from external damage and shall comply with the following requirements a The ducting shall be as short as practicable b The connections shall be mechanically clamped and shall not depend on adhesives or sealing compounds to retain them in place Protection in the form of a gasket shall be provided to prevent damage to the ducting material by the clamping device c The material of the conduit used for ducting shall be sufficiently strong to resist mechanical damage preserve venting integrity protect the piping or hose
84. ssembly and proof tested to not less than 27 5 MPa with fittings attached prior to installation 3 1 3 3 2 In addition to the requirements of 3 1 5 of this Standard flexible hose shall be installed in accordance with the following requirements 51 The exception being the flexible hose used between the towed and towing vehicle a The bend radius of the hose shall not be less than 35 mm or the manufacturer s recommended specifications b Flexible hose shall be secured to the chassis frame or vehicle body by clips secured at not more than 300 mm apart and shall be fitted prior to and after each bend c Such clips shall be of sufficient resilience and secured to the vehicle in such a manner so as to prevent lateral movement and damage to the hose and not work loose d The hose shall be located as far away as practicable from the exhaust system In no case shall it be closer than 100 mm Where the hose is situated between 100 mm and 200 mm from the exhaust shielding shall be provided which shall take the form of one piece of sheet metal located midway between the exhaust and fuel line 3 1 3 4 Inspection 3 1 3 4 1 At the time of periodic inspection the hose shall be inspected for twists kinks and damage or abrasions to the cover which expose the wire The hose shall be condemned on detection of any one of these defects 3 1 3 4 2 At no time shall flexible hose be placed back into service after removal from the vehicle the
85. ssibility of damage due to collision overturning or other accident Parts of the vehicle may be used to provide such protection to valves and fittings 63 9 2 4 Shielding A fuel cylinder shall be shielded if necessary against direct heat radiation from the engine and exhaust systems 9 2 5 Mounting A fuel cylinder shall be secured in place on the Construction Equipment Vehicles so as to meet the requirements of a loading test 9 2 6 Load test 9 2 6 1 A CNG cylinder shall be secured in place on the Construction Equipment Vehicles in a manner capable of withstanding without visible permanent deformation loadings in any direction equal to 10 times the filled weight of the cylinder 9 2 6 2 For this test the cylinder is to be empty of fuel and is to be secured in the manner covered by the manufacturer s instruction Loadings are to be applied in any convenient manner capable of being measured by gauges or weights 9 3 Fuel system 9 3 1 Components All fuel system components shall be fastened to the Construction Equipment Vehicle to minimize the possibility of loosening due to vibration 9 3 2 Securing and shielding Fuel lines shall be supported to prevent chafing and to maintain at least 50 mm clearance from exhaust and electrical system parts Refer 3 1 5 paragraphs a to f inclusive and j 9 4 Shielding Temperature pressure tests 9 4 1 The materials employed in the construction of Construction Equ
86. staller to undertake CNG conversion who meets the following requirements i Name and communication details like address telephone number etc of the installer ii Business profile 111 Qualification 1v Experience v Details of technical staff and equipment vi Specification of workshop land use certificate from appropriate authority The vehicle kit manufacturer or supplier shall submit the above information to the regional transport authorities Installer to carry out conversion installation as per Code of Practice for Use of CNG fuels in internal combustion engined vehicles AIS 028 Installer to carry out the inspection testing commissioning amp garaging repair of CNG system as per clause 7 amp 8 of AIS 028 Installer shall issue installation certificate as per Annexure VI of AIS 024 to the vehicle owner that the conversion kit has been fitted in safe and proper manner in compliance with Code of Practice for Use of CNG fuel in Internal combustion Engined Vehicles AIS 028 Installer to send a copy of installation certificate as per Annexure VI of AIS 024 and duly filled checklist as per Appendix A of AIS 028 for vehicles other than CNG buses Annexure VII of AIS 024 for CNG buses to RTO and Test Agency who has type approved the CNG conversion kit The record of conversion alteration of vehicles carried out by the kit installer shall be maintained and made available to the authorit
87. t CNG buses before registration by RTOs Reference to relevant clauses of Safety Code of Practice e g AIS 028 and guidelines issued by Central Government from time to time should be made wherever appropriate A Details of CNG Bus 1 a Name and address of chassis manufacturer applicable for new amp Converted Retrofitted in use b Name and address of retrofitter applicable for Converted Retrofitted in use c Name Converted Retrofitted in use and address of engine manufacturer applicable for Name of type approval agency Details of type approval certificate Name and address of bus body builder Name and address of approved inspecting agency at R T O Chassis and engine No T ON ON SR E t Year of manufacture B Detail of CNG System 1 Checking of Cylinders as per PESO vehicle testing agency approvals e Validity of PESO Certificate e Safety checks Check for corrosion on any CNG components mountings of gas circuit Check whether cylinder is securely mounted within the vehicle and check tightness of nuts and bolts Check whether minimum 5 mm clearance is kept between cylinders and vehicle body structure Distance between cylinder valve and bus body extremities shall not be less 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 mini
88. taining hard rubber equivalent material padding lining provided for inner side of the cylinder mounting band s a Name of manufacturer b Identification No c Type 31 Battery cut off switch if applicable a Name of manufacturer b Identification No c Type 32 Any other information Note In case of OE fitment if any of the above information is already covered in the information submitted as per AIS 007 only the reference need be given and it is not necessary to duplicate the information Mention NA Wherever not applicable Test Agency Manufacturer Document No indicating also revision status Signature Signature Name Name Designation Designation Date Date Sheet No of Annexure II Page 1 2 TECHNICAL SPECIFICATIONS OF VEHICLES Manufacturer s Name and Address Vehicle Data Model Type Year and Month of Manufacture Engine No Chassis No Engine Type Bore x Stroke mm No of Cylinders Displacement Compression Ratio Max Engine Output Max Torque Air Cleaner Oil Filter Fuel Filter Capacity of Cooling System Oil Sump Capacity Weight of Engine Complete Radiator Frontal Area Core Area Clutch Type Outside Diameter Gear Box Model Type No of Gears Gear Ratio 1 st pra rd qh 5th ph Reverse Front Axle Rear Axle Ratio Steering Steering Wheel Diameter Ratio Test Agency Manufacturer Document
89. test as per IS 14557 Any other tests as made applicable by y Government of India from time to time Test need to be done on Dual fuel mode Consumption of both Diesel and CNG fuel to be measured NA Not Applicable 40 AIS 028 CODE OF PRACTICE FOR USE OF CNG FUEL DEDICATED BI FUEL DUAL FUEL IN INTERNAL COMBUSTION ENGINED VEHICLES 1 General This code of practice may be called as Code of Practice for Use of CNG fuel in Internal Combustion Engined Vehicles This code of practice is applicable to vehicle categories as per AIS 053 1 1 Scope 1 1 1 This code of practice shall apply to the design construction installation operation maintenance inspection testing and fueling of compressed natural gas CNG systems where CNG is used either Dedicated Dual fuel bi fuel for internal combustion engines In general the Standard is directed towards vehicle installations 1 1 2 It is not intended to cover the areas where major structural modifications are to be carried out to the vehicle major structural modifications are those not defined in 1 1 4 Prior to commencement of such work guidance should be sought from the vehicle manufacturer 1 1 3 Special circumstances exist for construction equipment vehicles with internal combustion engines Accordingly a separate section is included to cover the special requirements of the construction equipment vehicles 1 1 4 Any alterations or modification to any vehic
90. the gas air mixer SERVICE FUEL LINE The fuel line running from the storage cylinder and terminating at the regulator SERVICE SHUT OFF VALVE A manually operated shut off valve fitted on the cylinder which can open or shut off the CNG supply for maintenance servicing or emergency requirements SHALL The word shall is used to indicate a requirement that must be adopted to comply with this Standard SHOULD The word should is used to indicate a recommended practice SHUT OFF VALVE A valve for stopping gas flow STATUTORY AUTHORITY The Government Department or agency responsible for the particular aspect See Appendix B UPSTREAM Is the direction against the flow of the stream 1 4 Special requirements The fitment of a CNG fuel system shall be prohibited in any vehicle with a passenger compartment heating system which draws air from the engine compartment unless the heating system is made inoperable and gas tight to the passenger compartment 2 CYLINDER 2 1 Design approval 2 1 1 Cylinders shall be approved endorsed by the Department of Explosives as per Gas Cylinder Rules 1981 as amended from time to time 2 1 2 The weight of the CNG cylinder s will affect the unladen weight of the vehicle and therefore consideration of the effect on the legal and manufacturer s rating and axle loadings should be considered 2 1 3 In no circumstances shall the vehicle s critical load distribution affecting
91. uel Bi fuel Dedicated fuel system 4 2 5 1 a Dual fuel type A Dual fuel engine operation means a two fuel system having diesel as a primary combustion fuel and CNG as supplementary fuel both in a certain proportion throughout the engine operation zone Such dual fuel engine may be operated on diesel stand alone mode b Bi fuel type A bi fuel system is defined as a system equipped to operate with either on CNG or some other fuel e g petrol 56 c Dedicated fuel type A dedicated system is defined as a system equipped to operate wholly on CNG 4 2 5 2 For Bi fuel type 4 2 5 2 1 A shut off device shall be installed in the bi fuel fuel system This device shall shut off the optional fuel supply to the engine when this fuel is not required 4 2 5 2 2 If the shut off device is in the form of a solenoid operated shut off valve it must be fitted between the fuel pump and the carburettor The valve shall be mounted securely so that its weight is not taken on any part of the carburettor or fuel lines 4 2 5 2 3 Where the shut off device is mounted remotely after the regulator flexible hose shall be used of sufficient length to accommodate engine movement In all cases the device shall be mounted in a position reasonably protected from damage in a collision and shall be as far as practicable from high tension electrical equipment 4 2 5 2 4 Bypass relief device A bypass relief device shall be installed in the fuel pump or betw
92. ylinder and vehicle structure c The force necessary to separate the cylinder from the vehicle shall not be less than 20 times the mass of the full cylinder in any direction The strength of the anchorages may be established by static test forces directed through the centre of mass of the cylinder d In the absence of testing or where calculations are impracticable the following design requirements shall apply i There shall be at least 4 points of attachment to the vehicle structure The spacing between these shall be sufficient to ensure the stability of the cylinder ii Where a cylinder is anchored to steel sheet metal the sheet metal shall be reinforced by a plate of not less than 3600 mm and a thickness of not less than 2 5 mm or appropriate thickness supported by the calculation or test report It is preferred that a round washer be used but where a square plate is fitted the corners shall be radiused Any such reinforcement plate washer shall be contoured to the shape of the sheet metal or chassis rail Table 1 49 Cylinder size Band dimensions Bolt or stud diameter for water capacity in ltrs Minimum nominal size strap or flange mountings Over up to and including minimum nominal size L mm mm 0 30 30 x2 10 30 100 30x3 10 100 150 50x6 12 Above 150 Specific design required 111 Where anchorage bolts pass through a hollow section provision shall be made to prevent colla

Finalized Draft AIS-024 SAFETY AND PROCEDURAL

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