WELCOME TO AKADEMI

SAGA

NGV INSTALLATION,
INSPECTION AND TROUBLE
SHOOTING
The gas fuels for automotive use are classified in 2 categories:

1.CNG@NGV (permanent gas)

2.LPG (Liquid gas)

Compared to the liquid fuels (petrol & gas oil) they have a lower
environmental impact.
 What is LPG?

LPG stands for Liquid Petroleum Gas. It is a by-product of the refining

of crude oil, which has a gaseous state at room temperature and
pressure. It is at a pressure of 2 Bar in its liquid state. The LPG used to run
motor vehicles is a mixture of propane gas and butane gas whose chemical
and physical properties enable excellent vehicle performance in terms
of power, engine agility and operation. It burns without leaving the carbon
residue in the engine that is responsible for premature wear; it increases
the life of the spark plugs, valves and pistons and preserves the properties
of the engine oil for much longer. Its combustion releases lesser
amounts of carbon monoxide, nitrogen oxides and un burnt hydrocarbons
than gasoline and diesel, and there is no production of aromatic
hydrocarbons, sculpture dioxide and particulate.
 What is Natural Gas?

Methane or natural gas is the utmost in environmentally friendly

fuels: one of the most plentiful in nature. In fact, Natural Gas
does not contain any impurities, sulphur, lead compounds or
aromatic hydrocarbons, resulting in extremely low levels of
exhaust pollution without odour, particulate and combustion
residue. The chemical composition of Natural Gas causes much
less production of CO compared to other fuels; it also reduces
the formation of ozone in the atmosphere.
 History of Natural Gas
• Founders – Lazzaro Spallanzani (1795)
• Energetic potentials – Alessandro Volta (1776)
• The first gas lighting system – William Murdoch (1806) Eng.
• The first steel gas pipeline – USA (1925)
• National Fuel in Italy – 1938
What is NGV ?

~Stands For Natural Gas for Vehicles.

~Used As Fuel For Vehicles In Some Countries For More Than

50 Years.

~More Than 3 Million Vehicles Worldwide Using NGV As Fuel.

~Same As Natural Gas Supplied To Power Stations, Industries,

Commercial Establishments And Households.

~Compressed And Stored At 3000 Psig Onboard Vehicles.

Also Known As Compressed Natural Gas (CNG).
 Advantages
Many are the advantages that derive from the use of CNG and LPG,
among which are:

• The inexpensiveness of consumption: all over the world the cost of

CNG and LPG is definitely lower than the one of petrol;

• The abatement of the polluting emissions;

• The absence of carbon deposits in the firebox and of corrosion

phenomena by the LPG and the natural gas, which are free from additives;

• The perfect mixture with air at all temperatures and perfect combustion;

• The lubricating properties of the engine oil maintained for a longer time
with clear benefits for the longevity of the engine’s life itself.
Why NGV ?….
~Environment - Reduces Air Pollution
Motor Vehicles Is Major Source Of Air Pollution (More Than 90 % Of
Air Pollutants Comes From Motor Vehicles).
~Energy - Security Of Supply/indigenous Supply
Transport Sector Is A Major Consumer Of Energy (41.1 % In 1999).
Mainly Petrol And Diesel.
Recoverable Gas Reserves (As Of 1. 1. 2000) Four Times Of Oil
(Oil = 3.42 Billion Barrels, Gas = 84.4 Trillion Standard Cu. Ft).
~Economics
Savings For The Nation
Savings In Oil Imports / Increase Exports Of Oil
Cheaper Source Of Energy
Reduces Health & Medical Care Costs
Reduces Cleaning & Maintenance Costs
Creation Of New Jobs
Potential For Spin-off Industries
Savings For The Customers
Savings In Fuel Cost
Savings In Car Maintenance Cost And Road Tax
NGV category

1. Mono-Fuel vehicle:
~Run 100% on Natural gas only.

2. Bi-Fuel vehicle:
~Can run on Natural gas or petrol, selectively.

3. Dual-Fuel vehicle:
~Can run on the mixture of diesel and Natural gas.

4. Hybrid vehicle:
~Can run on Natural gas with the electric motor.
 Comparison…
NGV LPG PETROL DIESEL

MAINLY METHANE, MIXTURE BUTANE & MIXTURE OF HIGHER MIXTURE OF HIGHER

COMPOSITION GASEOUS, PROPANE, HYDROCARBONS, HYDROCARBONS,
ODORANT ADDED LIQUID/GASEOUS, LIQUID, LIQUID,
ODORANT ADDED DISTINCT ODOR DISTINCT ODOR
SPECIFIC 0.7 1.86
HEAVIER THAN AIR HEAVIER THAN AIR
GRAVITY (LIGHTER THAN AIR) (HEAVIER THAN AIR)

OCTANE # (RON) 130 100 – 104 97 N/A

AUTO-IGNITION
630 480 – 540 456 338
TEMPERATURE

FLAMMABILITY
5% - 15% 2.1% - 9.5% 1.4% - 7.6% 0.5% - 5%
LIMIT

HEAT ENERGY 51.6 MJ/kg 49.55 MJ/kg 47 MJ/kg 45 MJ/kg

3000 psig 100 – 150 psig

STORAGE ATMOSPHERIC ATMOSPHERIC
(GASEOUS IN (LIQUID+GAS IN
PRESSURE (LIQUID) IN TANK (LIQUID) IN TANK
CYLINDER) CYLINDER)
Comparison Of Pollutants Level Emitted
NONMETHANE
CARBON MONOXIDE NITROGEN OXIDES
HYDROCARBON
(CO) (NO)
(NMHC)

PETROL BASE BASE BASE

LPG - 20% - 10% + 20%

NGV - 60% - 90% - 10%

DIESEL - 40% - 10% + 700%

(SOURCE : NATURAL GAS FUELS, USA, APRIL 1997)

NOTE :
THE POLLUTANTS ABOVE, ARE TOXIC ELEMENTS, POISONOUS AT HIGH LEVEL EVEN TO
HEALTHY PEOPLE, AFFECT LUNG FUNCTION, INCREASE RESPIRATORY ILLNESS IN CHILDREN,
CONTRIBUTE TO ACID RAIN FORMATION, INCREASE THE TOXIN LEVEL HARMFUL TO FISH AND
OTHER AQUATIC LIFE, CONTRIBUTE TO VISIBILITY IMPAIRMENT AND REDUCES OXYGEN
DELIVERY TO BODY AND TISSUES.
Fuel price
comparison…(Malaysia)
No Fuel Price/Liter (RM)
1. NGV 0.68
2. LPG 1.75 (1 Kilo)
3. Petrol 1.92
4. Diesel 1.58

I pay only RM0.68,

HOW ABOUT YOU?
NGV in Malaysia – Current status

~There Are About 22,522 Natural Gas Vehicles In

And Around Klang Valley ,Malacca,Johor Bharu,
N.Sembian & Penang.

~48 Public And 2 Private NGV Refueling Stations

Currently In Operation (Klang Valley 42, JB 5,
Seremban 2 and Penang 1)

~A Target Of 200 Stations To Be Built By Year

2008. (Nationwide)
 Vehicle Conversion to NGV

Vehicle Population as of October 2006 : 22,522

Taxis : 20,967
Enviro 2000 : 926
Private : 599
Bus : 30
 The Renault’s MPV ENVIRO 2000 NGV
Customer/User : KLIA Airport Limousine
Project Year : 2000
No of Vehicles : 1,000
Technology : France MATRA
Lead Time : 6 months

Enviro 2000 features:

•Operating range 380km

• convenient traveling distance
• Tank storage under floor pan (3unitsx47litres,36.9m3)
• hidden, not visible
• not sacrificing luggage storage
• External refueling valve (next to petrol filler cap)
• quick refueling procedure
• no need to open front hood
 The success story
Argentina started their NGV program in
1985, same as Malaysia. Today, after 19
years there are only 22,500 NGVs on
Malaysian road compared to more than
1,200,000 NGVs in Argentina
 VEHICLES POPULATION IN PENISULAR
MALAYSIA

Actual registered motorcar ( private) in 2005 : 537,900

Total Motorcar : 6 million

Klang Valley : 2.5 million
Johor : 700,000
Penang : 500,000

** Growth rate : 10% per/year

 Government incentives & legislations
to encourage use of NGV
~Import Duty And Sales Tax Exemption On Conversion Kits

~At Least 50% Of Petrol Retail Price

~Accelerated Capital Allowance For Purchase Of Monogas Buses

And Construction Of NGV Outlets

~Bus grant (RM50,000 per/bus) purchase of new Monogas NGV buses

~Bus grant (RM25,000 per/bus) conversion to NGV dual fuel

~Additional Reduction Of Road Tax From Existing Levels

Monogas Vehicle - 50% Off
Bi-fuel Vehicle - 25% Off
Dual-fuel Vehicle - 25% Off
The Malaysian Approach In NGV
Industry

National Petroleum Co.

Infrastructure Setting Up
(Oil & Gas)
NGV Station

NGV Consumers
 Where We Are Today
S t a t i o n U n d e r C o n s t r u c t i o n
( Target to be in operation by March ‘’07 )

1. PSS Kg. Baru Subang

2. PSS Kg. Axis Shah Alam
3. PSS Central Sugar, Shah Alam
4. PSS Desa Mentari, PJ
5. PSS Persiaran Bandar Baru Bangi
6. PSS Rawang Industrial Park
7. PSS Selayang By-Pass
S t a t i o n U n d e r C o n s t r u c t i o n
( Target to be in operation by March ‘’07 )

8. PSS Lot 219, Grand Saga Highway, Cheras

9. PSS Permai Jaya, Ampang
10. PSS Bt.8 Jalan Ipoh
11. PSS Sunmay Batu Caves, KL
12. PSS Bt.4 ½ Jalan Ipoh
13. PSS Jalan Kuari, Cheras
14. PSS Desa Cemerlang , JB
15. PSS Jalan Batu Pahat, Kluang
TYPES OF NGV REFUELLING STATIONS
 CONVENTIONAL STATION

 NATURAL GAS SUPPLIED THROUGH PIPELINES

 MOTHER STATION
NATURAL GAS SUPPLIED THROUGH PIPELINES
NATURAL GAS IS SUPPLIED TO DAUGHTER
STATIONS USING TRAILERS

 DAUGHTER STATION
RECEIVED SUPPLY OF NGV FROM MOTHER
STATION
 Criteria To Be NGV Converter

• Conversion Kit must be approved by SIRIM

• Cylinder must be approved by Department of Safety & Health (DOSH)

• Workshop must be approved by Road Transport Department (RTD)

- Category C

• The Installer must obtain MLVK Level 2 and “ Certified

Installer Certificate” from Tractors Malaysia
 NGV kit type

1. Carburetor type

2. Injection type
~ Mixer system
(Mechanical injection and Electronic injection)

~ Sequential system
(Electronic injection)
CARBURETTOR KIT
 System layout – Carburetor type

• Switch indicator

• Spark Timing Advance

• NGV Pressure Gauge

• Petrol Solenoid • Mixer • Pressure Regulator

 Petrol solenoid valve
This device positioned between the petrol
pump and the carburetor cuts off the flow of
petrol during gas operation. Available in two
versions, mod. 037 (inlet/outlet 6 mm in-line
with petrol flow) and mod. 031 (inlet/outlet ø 6
mm and ø 8 mm), both equipped with a
manual opening cock in the case of failure of
the electric device.

Mixer
Mechanical devices that, by using the
Venturi principle, ensure correct air/fuel
mixing in both stationary and dynamic
conditions. Each mixer is designed for a
specific vehicle in order to optimize both
gas and
INJECTION KIT (Mixer type)
 System layout- Injection (Mixer type)

• Switch indicator

• Mixer

• Stepper Motor

• Injector Emulator • STAP • Electronic Control Unit • Pressure Regulator

 Petrol-Gas switch
An electronic control module whose main functions are:
 Gas/petrol selector with 2 positions and gauge for the fuel being
used
 by means of 2 led;
 Petrol starting automatically passing over to gas on deceleration
with
 overlapping;
 Display of the level of gas in the tank by means of 5 led;
 Electronic safety device that cuts off supply to the LPG solenoid
valves if the engine stalls.

Injector emulator

The right emulator for each car

varies depending on the type of
Injection System involved in the
conversion.
Spark timing advance
processor

These devices change the car spark advance when running on natural gas and
restore the original spark advance every time you switch on to petrol supply.
The increase in spark advance during gas operation, which compared to
petrol is a fuel with a higher octane grade, improves engine performance.

Start petrol solenoid valve

This device positioned between the regulator
gas outlet and the mixer cuts off the flow of
NGV during starting and petrol operation.
Available in normal and oversize version,
both equipped with a carburetion adjustment
register.
OBD emulators
When running on CNG, these electronic devices
interact with the diagnostic ECU, emulating the
signals that are necessary to avoid the record of
false errors in the control unit. In this way the
petrol system works in optimal conditions, avoiding
drifts and false errors.

Mechanical devices that, by using the

Venturi principle, ensure correct air/fuel
mixing in both stationary and dynamic
conditions. Each mixer is designed for a
specific vehicle in order, together with the
regulator and LCS-V05 system, to
optimize both gas and petrol operation.
Spark timing advance
processor

These devices change the car spark advance when running on natural gas and
restore the original spark advance every time you switch on to petrol supply.
The increase in spark advance during gas operation, which compared to
petrol is a fuel with a higher octane grade, improves engine performance.

Start petrol solenoid valve

This device positioned between the regulator
gas outlet and the mixer cuts off the flow of
NGV during starting and petrol operation.
Available in normal and oversize version,
both equipped with a carburetion adjustment
register.
OBD emulators
When running on CNG, these electronic devices
interact with the diagnostic ECU, emulating the
signals that are necessary to avoid the record of
false errors in the control unit. In this way the
petrol system works in optimal conditions, avoiding
drifts and false errors.

Mixer
Mechanical devices that, by using the
Venturi principle, ensure correct air/fuel
mixing in both stationary and dynamic
conditions. Each mixer is designed for a
specific vehicle in order, together with the
regulator and LCS-V05 system, to
optimize both gas and petrol operation.
INJECTION KIT (Sequential type)
SEQUENTIAL
NGV system lay out
Change over switch

High pressure gauge

Gas control unit

 Reducer

The system reduces CNG gas pressure from 200 – 220 bar to 1.8 bar.
The pressure reduction unit is a water-gas heated two stage, servo-assisted
membrane unit.
The “servo system” keeps the gas outlets pressure constant, with varying gas
inlet pressure (cylinder CNG pressure) and at different engine loads.
The solenoid shut off valve cuts gas flow when the engine is switched off or
Petrol fuel is selected.
 Pressure sensor

The pressure sensor connects to the GAS Control Unit and measures
The difference in pressure between the Gas injectors and the intake
Manifold.
In sensor’s lower part you can find 2 nozzles identified by the label P and V:
~ connect the Gas pressure hose coming from the Gas injector rail to the
P (pressure) nozzle.
~ connect the intake manifold vacuum hose to the V (vacuum) nozzle.
High pressure and Level gauge sensor

Special NGV pressure gauge allowing to operate the

NGV change over switch, level indicator and warning buzzer/lights.
Change-over switch / Indicator

The change-over switch has got a :

1. Switch button
2. Gas power – Yellow LED
3. Level gauge – Red LED and Four green LEDS
4. Petrol power – Red LED
5. Petrol Back-up feature
 Injection unit (Injector)

The metering unit delivers the right volume of the gas to the engine. The
ECU provides the injectors with the electrical signals necessary to
precisely regulate gas flow to the cylinders.
 Injection unit (Injector)
Power : 12 V d.c
Gas Inlet : Male connector for rubber hose.
Gas outlet : Male connector for rubber hose.
Operating temperature : - 40° to 120°C.
Installation location : Rigidly mounted near the intake manifold.
Solenoids must be vertical.

Injection nozzles must be mounted a close as possible

to the cylinder head intake valves.

Gas hoses to the intake manifold must have the same

length and as short as possible.
Homologations : E4-67R-01 , E4-110R-00
 ECU
The ECU is controlled by a microprocessor,
that processes data coming from the various
system sensors (gas pressure, gas temperature
regulator temperature, RPM).

The ECU regulates the gas volume delivered

To the engine, by controlling the injectors opening
Times.
The ECU also manages the following function:
~ indication of fuel level inside the tank
Part No ~ automatic switching from gas to petrol
~ 4 cylinder : 410614 ~ activation of the gas system on the pre-setting
~ 6 cylinder : 410615 conditions.
SAFETY
Properties and Characteristics of CNG
Properties and Characteristics of CNG
Natural gas occurs underground and may be mixed with
petroleum.

Mixture of methane, ethane, propane and butane Natural

gas is mostly (85% to 96%) methane

55 - .65 (air = 1)
Since natural gas is lighter than air it rises when released
into the atmosphere
Both the fuel and vapors of Biodiesel, E85, and Propane are
heaver than air

Colorless and tasteless

Odorless (but odorants are added for safety)
Properties and Characteristics of CNG

Clean air benefits

66% less carbon monoxide (CO)
68% less non-methane hydrocarbons
(NMOG)
87% less oxides of nitrogen (NOx)
40% less particulate matter (PM10)

Does not contaminate ground water or soil

Is an EPAct alternative fuel
Properties and Characteristics of CNG

Natural Gas CH4

Propane C3H8
Gasoline C8H30
Diesel C14H30
Biodiesel (Palmitic) C15H31CO2CH3
Methanol CH3OH
Ethanol CH3CH2OH
Properties and Characteristics of CNG
Non-toxic

Simple asphyxiant
Inhalation is primary route of exposure

Overexposure symptoms: shortness of breath,

unconsciousness
CPR recommended to overcome over exposure

Compressed to allow maximum fuel storage

3000 or 3600 psi
CNG is 130 octane fuel
Properties and Characteristics of CNG

Burns with a pale, faintly luminous blue flame at 593° C

Gasoline 332o C
Diesel 52o C

Fuel-to-air ratio is 4% (LFL) to 16% (UFL)

Gasoline 1.3% (LFL) to 7.6% (UFL)
Diesel .3% (LFL) to 10% (UFL)
CNG Fueling Station Equipment
 CNG Fueling Station Equipment

Time - Fill
Time - fill dispenser
Example: school bus
 CNG Fueling Station Equipment

Time - Fill
Refueling appliance
FuelMaker: Individual
vehicle or small fleets
CNG Fueling Station Equipment

Gas dryer

Compressor(s)

CNG storage

Dispenser(s)
 CNG Fueling Station Equipment

Cascade Fast – Fill

Cyclical fueling patterns
Public fueling
CNG Fueling Station Equipment

Gas dryer

Compressor(s)

CNG storage

Dispenser(s)
 CNG Fueling Station Equipment

Card reader

Emergency shutdown system

Fire extinguisher
Emergency Action Plan
Emergency Action Plan

Identification of emergencies

Action items
Notification procedures

Evacuation procedures

Safety systems

Emergency event action items

Emergency Action Plan

Compressor

CNG storage tanks

Emergency Shutdown Devices (ESDs)

Fire extinguishers
Emergency Action Plan
Pre-planned evacuation route

Designated assembly area(s)

Street address of facility

Emergency Action Plan
Emergency telephone numbers

Fire department
Emergency medical help
Police
Maintenance
Adjoining facilities

Safety Signs
Emergency Action Plan
Equipment Inspection:
Defective equipment
Dispenser hoses
Fueling nozzle and receptacle

Report unsafe conditions to maintenance

technician or station attendant
Emergency Action Plan
Cell phones and static discharge danger :
CNG/air mixture is flammable like gasoline vapors

CNG Fueling system is sealed, so there is no air in

the fuel system at the station or on the vehicle

Nevertheless, it is advisable to turn off/do not use

cell phone during vehicle fueling

Do not re-enter vehicle during fueling

Keep ignition sources away from fuel

Do not light matches or smoke cigarettes
Do not use cell phones while fueling vehicle
Emergency Action Plan
Close nozzle valve

Turn dispenser quarter turn shut-off valve to

the off position

Disconnect fueling nozzle from vehicle and re-

attach to mounting bracket on dispenser

Report situation to facility maintenance and/or

station attendant
Emergency Action Plan
Evacuate immediate area of fire

Press ESD button

Prevent other people from entering the danger zone

Do not attempt to extinguish CNG fire without training

Emergency Action Plan
Do not attempt to disconnect fueling nozzle from
vehicle

Direct others to evacuate immediate area

Press ESD button

Call fire department

Press ESD button

Extinguish only if trained and it is safe to do so
Near equipment, extinguishing should be attempted
only by qualified fire fighters
Correct Use of Safety Equipment
Correct Use of Safety Equipment
Understand how to correctly operate safety equipment
Fire extinguisher
Emergency shut-down device

Fire Extinguisher
Located on or adjacent to fueling island
Used to eliminate air (oxygen) from fire
Driver must be properly trained to fight (extinguish)
a natural gas fire
Correct Use of Safety Equipment
Fire extinguisher(s) located at or near the dispenser
If flame is extinguished without stopping gas flow, air/fuel
mixure may reignite
Use a fire extinguisher only if properly trained to do so by
qualified person

Emergency shut-down device (ESD)

Located on or adjacent to fueling island
Activation will close at least two isolation valves, causing
the compressor and gas flow from storage to the dispenser
to stop
NGV Technology and Safety Features
NGV Technology and Safety Features
Understand how natural gas vehicles (NGVs)
work

Understand how NGVs differ from gasoline

and diesel powered vehicles

Be knowledgeable about the four types of on-

board fuel storage cylinders
NGV Technology and Safety Features
Fuel receptacle: Flow fuel from dispenser nozzle
into fuel storage cylinders
High-pressure fuel lines: flow CNG from fuel
storage cylinders to pressure regulator
Manual quarter turn shut-off valve: can stop the
flow of CNG from the fuel storage cylinders to the
pressure regulator

Pressure regulator: Provides fuel pressure

regulation to the fuel injectors

Fuel injectors: Flow CNG into the engine

cylinder for combustion
NGV Technology and Safety Features

NGVs have sealed fuel systems

No air or oxygen in fuel system

Vehicle fuel is in a gaseous form

If fuel leaks, vapors will float upward

Vehicle fuel requires 593o C to ignite

High temperature not usually available
How to Fuel a CNG Vehicle
How to Fuel a CNG Vehicle

Open the fuel door and remove the protective

cap on the vehicle fuel receptacle

Remove the fueling nozzle from the dispenser

Inspect the fueling hose and nozzle for damage

Place the nozzle on the receptacle and pull

back to insure it is secure
How to Fuel a CNG Vehicle
Turn fueling valve handle on the nozzle to open position

Turn dispenser fueling handle to the on position

After fuel stops flowing, turn dispenser fueling handle to

the off position

Turn fueling valve handle on the nozzle to the vent position

Remove the nozzle from the receptacle and place it back on

the dispenser

Replace the protective cap on the vehicle fuel receptacle

PERSONNEL SAFETY
Equipment and material requirement
Safety Equipment and Facilities :
Automatic shutoff equipment , automatic fire protection
( alarms )

Safety clothing :
Gloves , apron , boots/shoes , eye protection

Personal safety Equipment :

Safety glasses , face shield , earplugs , gloves
PERSONNEL SAFETY
Safety Training :
Fire safety , first aid including CPR , emergency procedures

Shop Safety :
Long hair , Jewelry , Tool location , Heavy objects

Tool Safety :
Proper tools , Safety Guards ,Trained usage

Fuel Safety :
Location of Tanks , Extinguishers , Containers ,
PERSONNEL SAFETY
Engine Safety :
Eye protection , Fumes
Repair Procedure :
Battery , Transmission
CYLINDER
Presentation Topics

CNG Fuel Properties

Fuel Tank Technologies (pictures)

Service Conditions

Tank Design Considerations

Testing of Fuel Tanks (videos/pictures)

In-Service Performance (pictures)

Cylinder life span

CNG Fuel Properties
CNG Fuel –Experience
Large-scale use since 1960’s

Some 3,500,000 CNG vehicles now in

operation worldwide

Mostly in Italy, Argentina, Brazil, Pakistan,

etc. as lower cost fuel

Growing rapidly for transit operations in

Europe as lower emission fuel

Some 7,500 fill stations

CNG Fuel –Temperature Effects

Typically stored at 3,600 psi at 21ºC

If ambient temperature goes up or down, pressure

also correspondingly goes up or down
CNG Fuel –Filling

During filling, gas heats up as it compresses in

the tanks

Typically, stations only fill to service pressure of

3,600 psi

End up with 3,600 psi at some elevated

temperature (say 38ºC)in the tanks

As gas cools to ambient (say 21ºF),pressure of

gas decreases

End result is less gas -instead of having a fill of

3,600 psi at 38ºF,one has say 3,400 psi at 38ºF
CNG Filling –Full Fills

To prevent under fills –2 approaches:

Tanks can be slowly filled to allow heat to dissipate

Tanks can be pressured beyond service pressure ,i.e.

fill so that one gets higher pressure at a higher
temperature, thus cooling to 3,600 psi at 21ºC

Tanks actually designed to be filled up to 1.25times

service pressure (all qualification testing done at
1.25 times)
Fuel Tank Technologies
Fuel Tank Technologies

4 basic types of tank designs

Which design to use depends on need to reduce

weight and how much can pay

All designs have equivalent safety ,as all meet

requirements of same standards

Design type can also determine how a tank maybe

handled ,and how it may be filled
Type 1 &Type 2 Tank Designs

Type 1 - All metal (aluminum or steel)

Cheap but heavy

Type 2 -Metal liner reinforced by composite wrap

(glass or carbon fiber) around middle (“hoop
wrapped”)

Liner takes 50% and composite takes 50% of the

stress caused by internal pressurization

Less heavy, but more cost

Type 3 Tank Design

Around entire tank (“full wrapped”)

Liner takes small amount of the stress

Light - weight, but expensive

 Type 4 Tank Design
Wrap around entire tank (“full wrapped”)

Entire strength of tank is composite

reinforcement
Service Conditions

Road conditions present a very severe environment

for pressure vessels

Temperature extremes (-40ºC to +85ºC in vehicles)

Multiple fills (pressure changes) = fatigue cracking

Exposure to road environments and cargo spillage

Vibration

Vehicle fires

Collision

Standards require tests or installation requirements

for all these conditions
Tank Design Considerations

Limited to life of vehicle

Alternative is over design to last forever

“Leak – Before - Break” so that if tank stays in service

beyond design life, and experiences excessive fill
cycles, will only fail by leakage

Fire protection provided by thermally-activated

pressure relief device (PRD) protecting every tank
Testing of Fuel Tanks
Performance Testing

Qualification tests required by standards to ensure

tanks and components will perform safely when
subject to automotive service conditions.

Automotive OEM will perform additional tests to

ensure the durability of the fuel storage system.
Hydraulic Pressure Cycle Testing

Test using water

instead of gas (easier
to pressure cycle)

Failure mode must be

leak, not rupture
Low Temperature Pressure Cycling

Hydraulic pressure cycle test

while the tank is chilled to -40ºC

Tank then heated to 65ºC

followed by more pressure cycle
testing
Drop Impact Testing
Appearance of Impact Damage After Drop Test

Carbon fiber composite

Type 4 design

Drop test performed with

tank EMPTY (most
severe condition)

Difficult to visually detect

Drop Test Failure During Pressure Cycle Testing

At location of impact damage,

tank bursts during
pressure cycling = failure
to meet test requirements
Environmental Exposure Test

Multiple Type 3 tanks sitting in

road salt bath and exposed to
various concentrated solutions

White pads contain battery

acid, fertilizer solution, gasoline,
etc.

While exposed to solutions,

Tanks are also being pressure
cycled with fluid to simulate filling
and emptying
Environmental Test Failure

Cracking of glass fiber by

acid environments –
note that the acid passed
through the protective
coatings being evaluated in
an attempt to protect the
glass fibers
CNG Permeation Test

Type 4 tank inserted in

sealed chamber to measure
amount of CNG that permeates
through plastic liner over time
Gunfire Test of CNG Tank
 Damage Tolerance –Gunfire Test

Type 3 composite tank

First bullet made 75 mm

cut in carbon fiber and
exposed aluminum liner

Second bullet caused

the release of the tank’s
hydrogen gas
 Hydraulic Crush Test (150,000 kgf)

Type 3 steel tank

Used hydraulic ram to

attempt crush of
pressurized tank

Test ended at 150,000

kgf when reinforced
concrete wall on
opposite side of ram
broke
 Abrasion Damage

Type 2 steel -
composite hoop
wrap tank

Tank dragged
on road under
vehicle after
support strap
broke

No effect on
burst strength
 Abrasion Damage

Type 4 composite
tank

Tank dragged on
road under vehicle
after support strap
broke

No effect on burst
strength
CNG Vehicle Collision – Type 1

Vehicle impacted at 80
km/h by gasoline
vehicle

Impact ruptured petrol

tank causing fire (note
scorch marks on
Type1 tank )

Tank PRD vented the

CNG
 Collision Damage

Type 4 composite
tank

The Civic was

crushed to the “B”
pillar behind the
driver’s seat

The driver walked

away.There was
no leak or rupture
of the natural gas
fuel tank or system
 Collision Damage

Type 4 composite
tank

Tank was mounted

on CNG bus roof

The bus impacted a

low overhang,
collapsing the roof
of the bus

Tank exceeded
minimum burst
pressure with
sustained damage
Bus Overpass Impact –Type 4

Tanks at full
pressure

Impact collapsed
roof and caused
severe abrasion
to outside tanks

Center tank
punctured (1”dia.
hole)releasing
CNG without
further incident
Type 1 Cylinder 40 litre capacity

Manufacturers
information
 Type 1 Cylinder 40 litre capacity
Tank usage type

Use by date
Cylinder life span
Type 1 Cylinder 20 litre capacity
 Type 1 Cylinder 20 litre capacity

Tank usage type

Use by date
Cylinder life span
Type 1 Cylinder 58 litre capacity

Cylinder valve
Type 1 Cylinder 58 litre capacity

Manufacturing
date
Thank you.