Compressed

Natural Gas
as a
Vehicle Fuel

Copyright 2004 AFV Institute with limited permission to U.S. DOE. 1

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. 2

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. 3

Module 1

Introduction
to
Compressed
Natural Gas

Copyright 2004 AFV Institute with limited permission to U.S. DOE. 4

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. 5

Why CNG?
 Domestically produced
 Large existing underground
distribution network in place
 Large installed base of vehicles in U.S.

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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)

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Why CNG? - 3
 Does not contaminate ground water or
soil
 Is an EPAct alternative fuel

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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. 10

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. 11

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. 12
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. 13
Appearance & Smell
 Colorless and tasteless
 Odorless (but odorants are added
for safety)

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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. 15

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. 16
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. 17
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

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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

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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

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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)

Copyright 2004 AFV Institute with limited permission to U.S. DOE. 24

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. 28

Facility Layout
 Compressor
 CNG storage tanks
 Emergency Shutdown Devices (ESDs)
 Fire extinguishers

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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. 31
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. 32

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. 33

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. 34

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. 35
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. 36

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. 37

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. 38

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. 40

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. 41

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. 42

Module 6

NGV Technology
and
Safety Features

Copyright 2004 AFV Institute with limited permission to U.S. DOE. 43

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. 44

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. 45

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. 46

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. 47

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. 48

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. 49

Module 7

How to Fuel
a
CNG Vehicle

Copyright 2004 AFV Institute with limited permission to U.S. DOE. 50

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. 51

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. 52

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. 53

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

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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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