Compressed Natural Gas as a Vehicle Fuel Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Copyright 2004 AFVI This material is intended to be used for in-house trainers of NGV fleet operators to train drivers and other interested parties on how to safely fuel natural gas vehicles. The material may not be used to develop or deliver commercial training programs or for any purpose other than stated above. Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Drivers Need to Know Introduction to natural gas Why CNG as a vehicle fuel Properties and characteristics of CNG CNG fueling station safety practices Fueling station safety equipment Emergency procedures Safe vehicle fueling procedures Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Module 1 Introduction to Compressed Natural Gas Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Module 1 Learning Objectives Understand why natural gas as a vehicle fuel Understand where natural gas comes from How natural gas is delivered to a CNG fueling station Environmental benefits Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Why CNG? Domestically produced Large existing underground distribution network in place Large installed base of vehicles in U.S.
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Why CNG? - 2 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)
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Why CNG? - 3 Does not contaminate ground water or soil Is an EPAct alternative fuel
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Module 2 Properties and Characteristics of CNG
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Module 2 Learning Objectives Understand natural gas and how it compares to other fuels Be familiar with the characteristics of natural gas Understand potential health and safety hazards
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Physical Properties Natural gas occurs underground and may be mixed with petroleum. Chemical composition – Mixture of methane, ethane, propane and butane – Natural gas is mostly (85% to 96%) methane
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Compared to Other Fuels Natural Gas
CH4
Propane
C3H8
Gasoline
C8H30
Diesel
C14 H30
Biodiesel (Palmitic)
C15 H31 CO2CH3
Methanol
CH3OH
Ethanol
CH3CH2OH Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Specific Gravity .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 Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Appearance & Smell Colorless and tasteless Odorless (but odorants are added for safety)
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Health & Safety Hazards Non-toxic Simple asphyxiant – Inhalation is primary route of exposure – Overexposure symptoms: shortness of breath, unconsciousness
CPR recommended to overcome over exposure Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Physical State Compressed to allow maximum fuel storage – 3000 or 3600 psi
Measured for sale in mass weight – 5.66 pounds = 1 gasoline gallon equivalent (GGE)
CNG is 117 octane fuel Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Flammability Burns with a pale, faintly luminous blue flame at 1100° F – Gasoline 630o F – Diesel 125o F
Fuel-to-air ratio is 4% (LFL) to 16% (UFL) – Gasoline 1.3% (LFL) to 7.6% (UFL) – Diesel .3% (LFL) to 10% (UFL) Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fire Extinguishing Fire extinguisher(s) located at or near the dispenser If flame is extinguished without stopping gas flow, air/fuel mixture may reignite Use a fire extinguisher only if properly trained to do so by qualified person Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Module 3 CNG Fueling Station Equipment
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Module 3 Learning Objectives Understand different types of fueling stations Be familiar with various components of a CNG fueling station
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Types of Fueling Stations Time - Fill – Time - fill dispenser • Example: school bus
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Types of Fueling Stations - 2 Time - Fill – Refueling appliance • FuelMaker: Individual vehicle or small fleets
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Types of Fueling Stations - 3 Cascade Fast - Fill – Cyclical fueling patterns – Public fueling
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Fueling Station Components Gas dryer Compressor(s) CNG storage Dispenser(s)
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Fueling Station Components - 2 Card reader Emergency shutdown system Fire extinguisher
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Module 4 Emergency Action Plan
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Module 4 Learning Objectives Know purpose and content of Emergency Action Plan Be familiar with emergency equipment Understand emergency actions
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Purpose of Emergency Action Plan Identification of emergencies Action items Notification procedures Evacuation procedures Safety systems Emergency event action items Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Facility Layout Compressor CNG storage tanks Emergency Shutdown Devices (ESDs) Fire extinguishers
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Facility Layout - 2 Pre-planned evacuation route Designated assembly area(s) Street address of facility
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Safety Practices Emergency telephone numbers – Fire department – Emergency medical help – Police – Maintenance – Adjoining facilities
Safety Signs Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Safety Practices – 2 Equipment Inspection: – Defective equipment • Dispenser hoses • Fueling nozzle and receptacle – Report unsafe conditions to maintenance technician or station attendant
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Safety Practices – 3 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
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fire Safety Rules Keep ignition sources away from fuel Do not light matches or smoke cigarettes Do not use cell phones while fueling vehicle
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Gas Release at Dispenser 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 Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fire Involving CNG 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
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fire During Vehicle Fueling Do not attempt to disconnect fueling nozzle from vehicle Direct others to evacuate immediate area Press ESD button Call fire department
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Combustible Debris Fire 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
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Module 5 Correct Use of Safety Equipment
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Module 5 Learning Objectives Understand how to correctly operate safety equipment – Fire extinguisher – Emergency shut-down device
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Correct Use of Safety Equipment 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 Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Correct Use of Safety Equipment - 2 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
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Module 6 NGV Technology and Safety Features
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Module 6 Learning Objectives 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
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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CNG Fuel System 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
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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CNG Fuel System - 2 Pressure regulator: Provides fuel pressure regulation to the fuel injectors Fuel injectors: Flow CNG into the engine cylinder for combustion
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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NGVs vs. Gasoline & Diesel Vehicles 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 1100o F to ignite – High temperature not usually available
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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On-Board Fuel Storage System Fuel storage cylinder types: – Type 1: All metal (steel or aluminum) – Type 2: Hoop-wrapped steel or aluminum – Type 3: Fully-wrapped steel or aluminum – Type 4: All composite (non-metallic)
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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On-Board Fuel Storage System - 2 CNG fuel storage cylinder useful life is 15 years from date of manufacture Visual inspection required by NHTSA at 36,000 miles or 36 months Fuel storage cylinders hold CNG at 3,000 or 3,600 psi @ 70o F
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Module 7 How to Fuel a CNG Vehicle
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Module 7 Learning Objectives Be familiar with fueling instructions Understand fueling nozzle/receptacle operation
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fueling Instructions 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 Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fueling Instructions - 2 Turn fueling valve handle on the nozzle to open position Swipe fueling card through card reader Turn dispenser fueling handle to the on position After fuel stops flowing, turn dispenser fueling handle to the off position Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fueling Instructions - 3 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
Copyright 2004 AFV Institute with limited permission to U.S. DOE.
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Fueling Nozzle operation Receptacle characteristics
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Fueling - 2 NGV 1 nozzle – Type 1 – Typical public fueling nozzle
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Fueling - 3 NGV 1 nozzle – Type 2 – Typical fleet fueling nozzle
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