CNG DSM Training

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CNG Cylinders:-

Capacity in Water Letter.

Body White Colour & Neck Red Colour.
Control Valve.
Burst Disc.
NRV.
Testing Period – 3 Years.
Max Working Pressure – 255Bar.
CNG Fill Pressure – 200Bar.
CNG Cylinder
Valve & NRV
 Agenda
Typical CNG Station.
CNG Filling
•
• What is CNG and its Properties.
• Dispenser Type.
SOP •
•
Dispenser & Filling Probe Handling.
Customer Interaction.

Safety • Use of Rubber Mat.

while Vehicle Hand Brake.

•
• Dispenser Operation.

Filling
• Possible Emergencies.

Past •
•
Possibilities of Accidents.
How to Handle Emergencies.

Accidents
• Learning's from Past Accidents.
• Evaluation Test.
Typical CNG Station
 What Is CNG? Its Properties
CNG:-
Natural Gas Compressed to 200 to 250 Bars.
Used as Automobile Fuel.
Environment Friendly Fuel.

Properties of Natural Gas:-

1. Highly Flammable : Auto Ignition at 540 ‘C

2. Lighter Than Air .

3. Colorless .

4. ODOURLESS , Odorized by Spot-leak 1007.

DISPENSER
 Refill CNG into NGV.
 Measure CNG.
 Dispense CNG at 200 Bar.
 Car Dispensers with Two
Filling arms (Hose / Nozzle).
 Bus Dispensers generally
with Single arm (Hose /
Nozzle).
 Dispenser Make in IRM:
 Parker.
 DISPENSER

Break Away
Rupees
And KG
ON – OFF
Push Button
DSM
Nozzle
DCP Fire Resting
Extinguishe Position
r

Dispense Two Way Ball

r crash Valve
Guard

n cy
rge h CNG Filling
e i tc
m
E Sw Hose
Emergency Shutdown Device - ESD
Always Operate In
Case of
Emergency like
Gas Leakage &
Fire.

Complete Isolation
from Incoming
Gas.

Reset after
Emergency is
Tackled by
Rotating in Arrows
Break Away Coupling
Disengage when
hose is pulled by
Vehicle.
Safety Device.
Main Line Break
away is large in size
as compared Vent
line Break Away.
Main Line Break
away contains High
Pressure.
In case of Hose
pulled by vehicle
Air Actuated Valve
These Valves are
Auto-operated, with
Electrical Signal.

While Filling CNG into

Vehicle these Valve
Operates in
Sequence of LB – MB-
HB.

These Valve Also

Isolates CNG Supply
to Dispenser when
ESD is Operated.
Filter
To separate Oil from
Gas.

Three Filters in Each

Bank.

Filters shall be
drained on daily
basis.
Drain Valve
Used to Drain Oil
and depressurize
system.

Installed at Outlet
of filter of each
bank.

These Valves Are

Connected to a
Single Drain Line.
Isolation Valve
Installed at Inlet
Tubes of Dispenser.

Manually Operated
Isolation Valve.

Used to Isolate Gas

Supply to Dispenser
in Maintenance or
Repair Work.
Main Isolation Valve
SS Tubing – High Pressure
SRV – Safety Relief Valve
Safety Device: To release excess pressure from
system.
Non Return Valve - NRV
Allows Gas Flow only One Direction.

FLOW
Pressure Transmitter
Measures and Control Gas Filling Pressure.
Mass Flow Meter

Measure Amount
Of CNG
Dispensed in
Kilograms (Kg).
CNG Metal Plate In Vehicles

Must Check

All dispenser operators are instructed for keeping practice of

Metal Plate In CNG Vehicles
Correct Metal CNG Plate
Metal Plate In CNG Vehicles
Metal plate shall be clearly visible
 R. C. book enclosed by Regional Transport
Office (RTO).
There shall not be any correction /
overwrite.
Vehicle Number should be same as
mentioned in metal plate.
Test date of cylinder
Due test date of cylinder
Difference between test date & due date
should not be more than 3 years.
NZS to NGV Nozzle
 Pressure Gauge
Indicates Pressure of CNG filled in Vehicle Cylinder.
CNG Filling SOP:-
Position of Driver and DSM
CNG Filling SOP
Check for Cylinder Metal plate and Cylinder.
CNG Filling SOP
Cover the Battery Terminal of NGV with Rubber Mat.
CNG Filling SOP
Check Condition of ‘O’ Ring
CNG Filling SOP
Insert the Nozzle into NGV Receptacle and
check for its fitness.
Put Three-way Valve in Filling Position and wait
for pressure to stabilize.
CNG Filling SOP
Show Initial Zero
and Pressure to the
NGV Customer.
Start The Filling.
Continuously
Monitor the CNG
filling and stand
near the Dispenser.
After Completion of
CNG Filling Press
Stop Button and Put
Three way nozzle in
Vent Position.
Customer Interaction:-

Always show Initial Zero reading before start of CNG

Filling to customers to avoid any
Misinterpretation.

Always Greet the customer with “WELCOME” before

filling and “THANK YOU” after filling.

Always Try to give tips regarding CNG Kit testing,

CNG Cylinder testing and Filling point position.
Customer Interaction
NGV Nozzle correct Installed
Safety while filling CNG Station.
Do NOT Allow Passengers Inside Vehicle.
Safety while filling CNG Station.
Do NOT Allow Passengers Near Filling Area.
Safety while filling CNG Station.
Always Use Rubber Mat
Safety while filling CNG Station.
Always Use Rubber Mat
Safety while filling CNG Station.
Position of CNG Filling Hose in Resting Condition.
Past CNG Accidents
Two Extra Cylinders – Surat, Gujarat
Cylinder Condition
BEST Bus Fire–Mumbai, Maharashtra
A BEST bus on Route Number 4
(Oshiwara to Church gate) caught fire
on 12th
th Jan 2011 morning at 7:45.

The CNG pipeline of the bus suddenly

broke resulting in leakage of gas.
Driver vacated the bus immediately.
But he started bus to move it aside on
the road, causing fire.
BEST Bus Fire–Mumbai,Maharashtra
Unsafe and Poor Installation

Refueling valve without Dust plug Improper Electrical Wiring

Spark Plug without CAP Open Joints

In Case Of Emergency
at
CNG Station
In Case of Gas Leakage
 Operate ESD (Emergency

Shut Down devices).

 ESD are placed at three

different places:-
compressor, Dispenser.
 In case any incident,
press this switch.
 This will stop electric
supply to compressor.
Do Always
Remove passengers from Buses/Auto/Cars before filling and make them stand at
safe distance.

Engine must be switched off before starting filling of Vehicle. Keys should be
removed from vehicle before filling.

In case of doubt, filling of new Buses/Pvt. Buses be done after proper verification.

Stop the filling of Vehicle if any abnormality is found i.e. leakages from
tubing, Abnormal noise, Smell, Vibrations etc.

Do not allow idling people near the Dispenser/Station. Be Cautious to fill the
vehicles without RTO registration.

While filling the vehicle, driver should stand near filler for any immediate
assistance/clarification.
Safety Device at CNG Station
ESD – Installed At Dispenser and Compressor.

Wind Shock.

Fire Buckets.

Fire Extinguishers.

CO2 Flooding System.

Safety Signs
Safety Device at CNG Station
ESD – Installed At Dispenser and Compressor.
Safety Device at CNG Station
Wind Sock : Direction of wind
Safety Device at CNG Station
Fire Buckets
Fire Extinguisher

Type of Fire Extinguisher

DCP CO2 FIRE EXTINGUISHERS
DISCHARGE LEVER
PRESSURE
GAUGE
(not found on
DISCHARGE LOCKING
CO2
PIN
extinguishers)
AND SEAL
CARRYING
HANDLE

DISCHARGE HOSE DATA

PLATE

DISCHARGE BODY
NOZZLE
Fire Extinguishing Method
CLASSIFICATION OF FUELS
CLASS TYPE OF FUEL EXAMPLES

A-SOLID Fuels which are solid in state Wood, Paper, Cotton,

on burning they leave carbon Charcoal, etc.
as residue

B-LIQUID Flammable Materials which Petrol, Diesel, Paint, Spirit.,

are in Liquid state etc

C-GASES Flues which are in gaseous LPG, Acetylene, Methane,

state Butane etc.

D-METALS Metal which can burn Transformer, Generators,

Panel Boards, etc
D

In the latest classification of fuels, Class E is removed as electricity is not a fuel it is a

source of heat.
MEDIAS OF FIRE FIGHTING
WATER : for Class ‘A’

FOAM : for Class ‘B’

POWDER: for Class ‘B,C,D,’

Special
powder for class’ D’

CO2 GAS : for Class B,C,E.

MEDIAS OF FIRE FIGHTING
Type of Ext. Extinguishing Extinguishing Suitability on different Class
Agent Effect Classes of fire

Water Water Cooling Wood, Paper and Cloth A

Foam Mechanical Blanketing Wood, Paper, Cloth and AB
Foam Flammable Liquids
Powder Dry Chemical Blanketing Flammable liquids, Gases BCD
Powder Combustible Metals,
Electrical Installations,
Motors & Switch gears
Gas Carbon Blanketing Flammable liquids, BCE
dioxide Flammable Gases,
Electrical Installations,
Motors & Switch gears

*in the latest classification of fuels, Class E is removed.