SAFETY CHECKLIST FOR COMPRESSED NATURAL GAS (CNG) VEHICLES

SAFETY MEASURES

• Always use an approved CNG kit & cylinder. It is dangerous and illegal to use
substandard cylinders and fittings.
• Do not install LPG, Propane or any other cylinder in place of a CNG cylinder. It is unsafe
and unlawful.
• It is advisable to have insurance coverage for the CNG kit along with the
vehicle/accessories.
• Always, park the vehicle at least 6 meters away from sources of ignition (fire).
• Always refer to the CNG kit supplier’s manual for operating instructions and do not do
trouble-shooting yourself, other than that recommended by the manufacturer.
• Be aware of the location and operation of the cylinder valve, master shut-off valve, and
burst disc in the CNG system.
• Ask your mechanic to identify these parts for you. It would be helpful for emergency
handling of any CNG leak.

SAFETY CHECKS

• Make sure that the clamps are tight and cylinder fixed properly and safely.
• Confirm that cylinder valve is safe and valve wheel is in place.
• Ensure that gas tubing is intact and supported properly.
• Check for gas leakage from the kit by using soap solution.

IN CASE OF GAS LEAKAGE FROM CNG KIT

• Check out of the vehicle.

• Do not start the vehicle. Push vehicles to a place outside the station in open Air.
• Stop all activities in the vicinity, which can provide a source of ignition, e.g. smoking,
use of mobile phone etc.
• Close down the cylinder valve/ master shut-off valve in the CNG system to control the
leakage.
• Call CNG kit retrofitter to repair the same.

IN CASE OF FIRE

• Evacuate the vehicle and surrounding place.

• Take help of firefighting experts – 101.
• Extinguish the fire with water/fire extinguishers.
• If feasible, close down the cylinder valve/ master shut-off valve in the CNG system to
control the gas leakage.
 STATUTORY REQUIREMENTS

• Endorsement of CNG mode in Registration Certificate.

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

Vehicular Use of Compressed Natural Gas

1. Check your cylinder and kit certificate.

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

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

2. Use only approved CNG kits.

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

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

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

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

• There should be no leaks in the fuel system.

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

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

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

H.1. Dos and Don'ts

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

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

Four Types and Intervals for Inspections

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

What Is Covered in the Detailed Visual Inspection?

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

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

• PRDs, Vent Lines and Caps

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

What Records are Required?

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

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