Safety Manual EKCMKTWI01 PDF

EKC International FZE
Safety Instructions for

Handling and Inspection
M anual for Type 1
On-Board CNG Cylinders
Table of Contents
1.0 Compressed nat ural Gas (CNG)

2.0 Why CNG
3.0 Compressed Nat ural Gas (CNG) Cylinders for Nat ural Gas Vehicles
4.0 Terms and Definit ions
5.0 Sensit ivit y of cylinder mat erials t o operat ing condit ions and solut ions
Installation
6.0 Cylinder M ount ing
7.0 Cylinder Shielding
8.0 Cylinder handling
9.0 Cylinder Defueling
10.0 At mospheric Vent ing Equipment
11.0 Emergency defueling procedure t o at mosphere
12.0 Scheduled defueling procedure
Inspection
13.0 Cylinder Inspect ion
14.0 Guidelines for Visual inspect ion
15.0 General Visual inspect ion
16.0 Det ailed Visual Inspect ion
17.0 Classificat ion of Visual Damage
18.0 Cylinder Dest ruct ion
19.0 Hydrost at ic t est ing
20.0 Acoust ic Em ission Test ing
Damage
21.0 Types of Cylinder Damage
22.0 Surface corrosion in st eel cylinders
23.0 Fat igue cracks
24.0 Impact Damage
25.0 St ress Corrosion
26.0 Fire and Heat Damage
27.0 Prot ect ion and inspect ion of PRD and cylinder valves
28.0 Handling and St orage of Cylinders.
1. Compressed Natural Gas (CNG)
CNG is a nat ural gas w hich is a mixt ure of different gases mainly M et hane (90-92%). It is
available in many count ries under t he eart h in abundance. It is called as Green Fuel due
t o it s low emissions w hen used in Int ernal Combust ion S.I. Engines. CNG is m uch safer
t han ot her fossil fuels in t he event of a spill (nat ural gas is light er t han air, and disperses
quickly w hen released).
CNG is made by com pressing nat ural gas (w hich is mainly composed of met hane [CH4]),
t o less t han 1% of it s volume at st andard at mospheric pressure. It is st ored and
dist ribut ed in hard cont ainers, at a normal pressure of 200–220 bar (2900–3200 psi),
usually in cylindrical or spherical shapes.
2. W hy CNG
Salient feat ures of CNG are know n w orld-w ide by all aut om obile manufact urers and
users.
The major t hreat s t o urban air qualit y are heavy dut y diesel vehicles. Sw it ching over
from Diesel t o CNG in HM V w ill be m ore beneficial t o t he air qualit y and noise reduct ion
(due t o changed engine combust ion) as w ell, w here diesel pow ered HM V generally are
considered t o be a big nuisance.
CNG is now being used in t radit ional gasoline int ernal com bust ion engines t hat have
been convert ed int o bi-fuel vehicles (Gasoline/ CNG). Nat ural gas vehicles are
increasingly used in Asia, Europe and Sout h America due t o rising gasoline prices.
In response t o high fuel prices and environment al concerns, CNG is now being used also
in light -dut y passenger vehicles and pickup t rucks, medium-dut y delivery t rucks, t ransit
and school buses, and t rains.
Techno-commercial advantages of CNG as auto-fuel
Clean burning fuel:-It is clean, high oct ane eco-friendly, non-convent ional and most
suit able fuel for aut omobiles. Having ant i knock propert ies due t o it s fuel charact erist ics
reduce carbon deposit ion inside t he engine w hich helps in good cooling because t he
carbon pat ches do not conduct heat as much as t he met al of t he engines. CNG as and
alt ernat ive gaseous aut omot ive fuel is useful for t he cit y t ransport , delivery t rucks,
municipalit y t rucks, and many ot her ut ilit y vehicles including Saloon Cars, Three
w heelers, Aut o Rikshaw s and Tw o w heel m ot orcycles in cit ies.
Less pollution : - CNG reduces pollut ion because it is complet ely burnt out during
combust ion in t he engine and hence emit s much less pollut ant s compared t o ot her
fossil fuels like pet rol or diesel
Engine life :-CNG gives increased engine life.
Pure and full:-In case of CNG t here is neit her adult erat ion possibilit y nor pilferage.
Energy consumption :-1.39 Lt r of diesel is equal t o 1kg of CNG and 1.95 Lt r of Gasoline
Engine specifications: - Aft er conversion t he specs do not change and Borex St roke
remains t he same
3. Compressed Natural Gas (CNG) Cylinders for Natural Gas Vehicles
CNG cylinders are made t o cont ain compressed high-pressure nat ural gas. The high
pressure gas exert s great amount of forces on t he w alls of t he cylinders. To w it hst and
t hese forces, cylinders are made of t hick-w alled, high st rengt h mat erials such as St eel,
Aluminum or com posit es.
The most w idely used NGV cylinders are made of st eel and have a long hist ory of NGV
service
Pict ure of Type 1 CNG Cylinders Cut Sect ion of t ype 1 CNG Cylinder
Cut Sect ion of Type 1 CNG Cylinder Neck Cut sect ion of t ype 1 CNG Cylinder
bot t om
70 t o 80 % of all t he cylinders used in NGV service t oday are made of Seamless st eel
(Type 1). Type 1 CNG cylinders are re-know n for t heir est ablished safet y performance,
mat erial and design charact erist ics. They are produced using seamless t ubes, billet
piercing and plat es. Every process has it s ow n pros and cons.
The most w idely used manufact uring process is hot spinning of seamless t ubes. Wall
Thickness is designed t hrough t he relevant guidelines of various manufact uring
st andards.
The st andards are count ry specific and differ from count ry t o count ry. The most w idely
used st andards are ISO 11439, ISO 9809, EN: 1964, NZS: 5454, ECR 110, IRAM (On-
Board) and ot her NGV st andards.
Approval Process
As per t he relevant st andard agreed bet w een the cust omer and t he manufact urer a
t echnical file is prepared for approval by relevant inspect ion agency. The t echnical file
consist s all t he relevant design paramet ers, manufact uring process, mat erial
composit ion, QAP, det ailed dimensions and ot her specificat ions like Threading det ails,
Working Pressure, Test Pressure.
4. Terms and Definitions
All met al Cylinder : A cylinder t hat is made from met al only

Acoust ic emission : A form of non-dest ruct ive cylinder inspect ion
Composit e Cylinder : A cylinder made ent irely from non-met allic
M at erials such as plast ic and composit es
Aluminum : A mat erial used t o make cylinders
Carbon fiber : Type of fiber used t o w rap composit e cylinders
Composit e : -----------------------------------------------
CNG : Compressed Nat ural gas St ored at high pressures
Condemned Cylinder : A cylinder t hat must be removed from service. The
cylinder is considered condemned w hen it
damaged beyond repair
Corrosion : Process t hat refers t o oxidat ion of mat erials
primarily in w et environment s.
Cylinder : The t hick w alled pressure vessel used t o st ore
Compressed nat ural gas.
Cylinder St andard : Document used t o guide t he design, const ruct ion
and use of cylinders.
Defueling : The process of removal of CNG from t he cylinders
Dest royed : The process of cut t ing t he cylinder int o t w o or
Drilling a hole complet e t hrough t he cylinder t o
M ake it unusable.
Domes : t he curved port ion of t he cylinders
Fat igue : Cylinder damage t hat occurs by repeat ed filling and
Expending t he fuel (Pressure Cycle).
Fuel St orage syst em : Cylinders used t o st ore CNG on NGVs. A NGV can
One or more cylinders t o st ore CNG.
Fuel Delivery Syst em : The syst em t hat delivers fuel t o t he engine,
Includes t ubing, valves, regulat ors, filt ers.
Galvanic Corrosion : Corrosion t hat occurs w hen different mat erials
come int o cont act .
Hoop – Wrap : The w rapping used t o w ound t he cylinder, only t he
Side w alls are w rapped leaving t he domes.
Hoop w rapped : A cylinder t hat used hoop-w rap for
Cylinder reinforcement
Hydrost at ic t est : A t est performed on a cylinder w hen t he cylinder is
Pressurized hydraulically t o at least 1.5 t imes t he
Service pressure and t he cylinder volumet ric
Expansion is used t o det ermine it s condit ion.
Impact Damage : The damage caused by dropping t he cylinder or by
A blow from anot her object .
Level 1 Damage : M inor damage t hat is considered normal and

Should have no adverse effect on t he safet y of t he
Cylinder and it s cont inued use.
Level 2 Damage : M oderat e damage t hat requires t he cylinder t o be
Repaired and re-qualified before ret urning t o
Service.
Level 3 Damage : Severe damage w hich is not repairable. The
Cylinder is unfit for cont inued service and m ust be
Condemned.
Liner : An int ernal component of cylinder made from
M et al and plast ic w hich provides st ruct ural support
M anufact urer’s Label : The label cont aining t he official markings as
Required by t he cylinder st andard.
M ount ing Bracket s : A device used t o secure t he cylinder t o t he
Vehicle.
Nat ural Gas Vehicle : Vehicles t hat use nat ural gas as fuel
Pit t ing : Type of localized corrosion damage t hat occurs in
M et al cylinders
Port s : The opening at t he end of t he cylinder in w hich
Valves, pressure relief devices and plugs are
Inst alled
Pressure Relief : A device int egrat ed w it h cylinder valve w hich w ill
Device (PRD) release t he gas in an emergency, such as fire.
Reject ed Cylinder : A cylinder t hat must be removed from service and
Evaluat ed furt her before final inspect ion.
Road Debris : M at erial such as small rocks, st ones t hat have t he
Pot ent ial t o cause damage t o t he cylinders.
Service Life : The service life of t he cylinder as indicat ed by t he
M anufact urer’s label.
Service Pressure : The service pressure is t he pressure at a uniform
Gas t emperat ure of 70o F and full gas cont ent .
This is t he nom inal cylinder pressure rat ing.
Shielding : St ruct ure const ruct ed and inst alled on a vehicle t o
Prot ect and shield t he cylinder from road debris
Or any ot her ext ernal object .
Side w all : The cylindrical port ion of t he cylinder
Solid Plug : A t hreaded plug used t o prot ect t he cylinder port
St eel : M at erial used t o make cylinders and liners
St ress Corrosion : A form of cracking t hat occurs as a result of
Cracking combinat ion of st ress and a corrosive environment
Type 1 : Classificat ion for cylinder t hat is const ruct ed solely
from met al. Also know n as all met al cylinder.
Type 2 : Classificat ion for cylinder t hat is const ruct ed using
A met al liner and a composit e hoop-w rap. Also
Know n as hoop-w rapped cylinder.
Type 3 : Classificat ion for cylinder t hat is const ruct ed from a

M et al line and a composit e full w rap. Also know n
as fully w rapped cylinder
Type 4 : Classificat ion for cylinder t hat in const ruct ed from
A plast ic line and a composit e full w rap. Also
Know n as an all-composit e cylinder.
Thermal Trigger : t he port ion a of t hermally act ivat ed pressure relief
Device t hat is act ivat ed by excessive heat .
Valve, manual : A device inst alled on a cylinder t o cont rol flow of
Gas t o and from t he cylinder. The device is
Operat ed M anually w it h a knob.
Valve, solenoid : A device inst alled on a cylinder t o cont rol flow of
Gas t o and from t he cylinder. The device is t uned
on and off elect ronically.
Visual Inspect ion : A form of inspect ion w here a t rained inspect or
Examines a cylinder for signs of damage
Vent Line : A high pressure line from a pressure relief device
To a locat ion out side t he vehicle
5. Sensitivity of cylinder materials to operating conditions and solutions

Summary of Sensit ivit y of Cylinder M at erials.
M at erial Possible Damage Solut ion

Steel M ay experience Ensure steel is painted
Corrosion of exposed And cylinder is not in direct
Surfaces contact w ith other metals.
Impact Damage Ensure Cylinders are

protected from road Debris
And other external Objects.
Use Cylinder Shields.
Fire / Heat damage Ensure Cylinders are not

installed near the vehicle
exhaust pipe. Perform
periodic visual inspection.
Weathering
Cylinder surface may get
affected by ultraviolet
radiation if exposed to direct
sunlight. Use periodic
Inspection of external coating.
Chemical Attack Avoid exposure to harsh

chemicals, automotive fluids
and battery acids. Do periodic
inspection, check for pitting,
discoloration of cylinder
surface, signs of oxidation in
case due to prolonged
exposure
Abrasion Abrasion may occur due to

continuous rubbing of cylinder
w ith the road surface or some
other material in an event of
an accident or insufficient
ground clearance. Ensure
proper clearance w hen
vehicle is loaded to gross
w eight limit.
6. Cylinder M ounting
Proper care should be t aken w hen m ount ing cylinders
• The cylinder support mechanism should be st rong enough t o w it hst and force
equal t o 8 t imes t he cylinder w eight .
• Should allow liquids t o drain, accum ulat ion of liquids like w at er can lead t o
rust ing.
• M ount ing should be done in such a w ay t hat cylinder markings are easily
accessible and can be read w it hout much effort .
• Prevent abrading, minimize and w it hst and vibrat ions.
A Typical poor inst allat ion and m ount ing problem s are illust rat ed follow s:
No shielding
Flimsy home made

Bracket s
No rubber
Gasket s
Example of a poor Cylinder Installation.

7. Cylinder Shielding.
Cylinder Shielding should be used t o prot ect t he cylinder.
• Damage from road Debris

• Damage from Vehicle cargo
• Weat her element s
• Exhaust Heat
• Harmful Liquids
• Excessive sunlight
• From each ot her, if more t han one cylinder is inst alled.
Shielding is primarily used for cylinders t hat cont ain composit e mat erials. But it is a good
pract ice t o use shielding for Type 1 cylinders especially in cases of underbody
inst allat ions.
8. Cylinder handling
It is not recommended / advised t o remove cylinders from t he vehicles except in t he

follow ing emergency scenarios
• If vehicle has been involved in an accident or fire

• Vehicle maint enance requires cylinders t o be rem oved
• Cylinder inspect ion or re-t est ing is required
• Irreparable damage t o t he cylinder and t he affect ed cylinder is condemned.
If t he cylinder is t o be rem oved, t he follow ing precaut ions have t o be t aken. Only
aut horized t rained personnel should be allow ed t o handle t he cylinders
• Cylinders should not be dropped

• Cylinders should not be dragged
• Cylinders should not be lift ed by using t he at t ached valves / PRD as leverage or
support .
• Cylinders should not be rolled off st orage.
9. Cylinder Defueling
In t w o cases cylinders must be defueled (Depressurized)
a. Emergency defueling
b. Scheduled defueling
Emergency defueling must be performed w hen vehicle is involved in an accident

/ collision or fire at t here is a need t o remove CNG from t he cylinder t o prevent
immediat e hazard t o people or immediat e surrounding.
A scheduled defueling is planned removal of CNG from t he cylinder w hich may be

required in t he follow ing event s.
• Test ing
• To ret urn t he cylinder t o t he manufact urer
• To carry cert ain maint enance w ork as per manufact ures’ guidelines.
• When cylinder is t o be condemned.
Cylinder defueling is not required for rout ine visual inspect ion. In cases w here defueling
becomes absolut e necessit y t he local aut horit ies should be consult ed for guidance and
recommendat ions. Vehicle manufact urer’s inst ruct ions should also be review ed for
proper vent ing procedure. Use of proper t ools and st eps are of out most import ance.
Special care should be given t o elect rical grounding t o prevent gas ignit ion because of
st at ic elect ricit y buildup.
10. Atmospheric Venting Equipment.
The use of at mospheric vent ing of nat ural gas t o depressurize a CNG cylinder must be
done w it h ext reme care. Improper equipment or procedure increases t he risk of gas
ignit ion from nearby ignit ion sources such nearby flames, st at ic discharge et c,.
A st at ic elect rical discharge can build up w hen vent ing gas. This elect ric charge
can ignit e nat ural gas.
General Atmospheric Venting Equipment
A schemat ic diagram of a t ypical vent ing syst em is show n above.
The syst em w ill also include t he follow ing equipm ent .

• On-Board defueling connect ion inst alled on t he vehicle
• Vent pipe. The pipe t ypically should be 2-inch in diamet er and should be properly
support ed by a fix st ruct ure such as a w all. The pipe should ext end a minimum of
2 feet in height t han t he support st ruct ure. The pipe must be elect rically
grounded and no ignit ion source should be near t he syst em.
• Elect rical ground connect ion consist ing of a minimum 2 gauge or heavier copper
w ire at t ached at one end t o a rod or anot her suit able elect rical ground. The
ot her end should be clamped t o t he vent ing pipe and t he cylinder valve.
• A high pressure flexible hose
• A manual valve t o cont rol t he gas flow .
In addit ion t o t he above it ems, it is recommended t o keep t he follow ing safet y

equipment lose by
• A port able fire ext inguisher
• Past e NO-Smoking and “ Flammable Gas” signs near t he designat ed area.
If t he cylinder is not mount ed on a vehicle it should be properly rest rained as it may

move if t he gas is released at a fast rat e.
11. Emergency Defueling Procedure t o At mosphere
Emergency vent ing procedures should be used in sit uat ions w here t here is an absolut e
need t o remove CNG form t he cylinder immediat ely and it is not possible t o follow t he
normal recommend defueling procedure
The general procedure for emergency defueling is as follow s:

• Ensure t hat an emergency elect rical connect ion has been est ablished bet w een
t he cylinder, t he vent syst em and eart h ground.
• Connect t he on-board defueling connect ion t o t he vent syst em suing a high
pressure flexible hose.
• Open t he hand valve t o release t he gas. Adjust t he manual vale t o have a st eady
flow of gas. Transfer t he gas at a slow rat e t o prevent freezing. If elect ronic
solenoid valves are used t hen consult vehicle manufact urer for informat ion.
• Allow t he on-board st orage syst em t o vent complet ely.
• Disconnect all t he connect ions once t he vent ing is complet e.
12. Scheduled Defueling Procedure.
Scheduled defueling is t he preferred met hod of depressurizing cylinders. In t his process

t w o st eps are involved.
St ep1.
Run t he vehicle t o reduce pressure. M ove t he vehicle t o an out door
Locat ion and run t he vehicle t o use as much CNG as possible.
St ep2.
Residual gas removal. This can be done by safely vent ing t he gas t o t he
At mosphere.
St ep 1 w ill not vent t he gas complet ely. The residual gas must be vent ed t o at mosphere
using t he at mospheric vent ing procedure.
13. Cylinder Inspect ion.
All cylinders are designed w it h high safet y fact ors and undergo st ringent qualit y t est s in
all st ages of t he manufact uring process. The cylinders need t o be periodically examined
/ ret est ed every few years* t o ensure safety all t hrough out t heir service life. Inspect ion
det ermines t heir general condit ion and fit ness for cont inued usage.
There are t hree t ypes of inspect ions (See t able below ) w hich can per carried out t o
assess t he cylinder’s overall condit ion and fit ness levels.
Inspect ion Descript ion Removal of Cylinder Frequency

Type From Vehicle
Visual Primary Inspect ion No 3 years or 36000
M et hod, K.M (w hich ever is
recommended by earlier)
all manufact urers
Hydrost at ic Required by vehicle Yes 5 years for Type 1

or cylinder M et al cylinders.
manufact urers.
Should be done as
per t he guidelines
of local regulat ory
aut horit y.
Acoust ic Em ission Non Dest ruct ive No M ay be performed

t est t hat may be along w it h visual
done in conjunct ion inspect ion
to supplement
visual inspect ion.
* The Durat ion of Periodical Inspect ion/ Re-t est ing is defined by t he regulat ory aut horit y
of each count ry.
NGV St andards and ISO 11439 define t he periodic inspect ion of CNG cylinder every 3
years unt il t he specified service like of t he cylinder.
M any count ries w here t he service life of t he CNG Cylinder is undefined insist hydrost at ic
re-t est ing of cylinders every 5 years.
14. Guidelines for Visual inspect ion.
Visual inspect ion can be carried in t w o w ays.
• Periodic General Inspect ion
• Periodic Det ailed Visual inspect ion
Element s of Visual Inspect ion

Inspect ion Type Descript ion Frequency
General Visual Inspect ion performed by During rout ine
Inspect ion vehicle ow ners, fleet maint enance or as specified
managers and t echnicians by t he safet y plan
t o check for any signs of
damage t o t he cylinder.
Det ailed Visual Det ailed inspect ion should 3 years or 36000 K.M
Inspect ion be performed by t rained (w hich ever comes first )
t echnical st aff as
recommended by t he
manufact uring st andard,
local regulat ory aut horit y
or from cylinder
manufact urer.
Det ailed visual inspect ion is must for NGV cylinders and should be carried out at
recommended frequency.
Visual inspect ion should become an int egral part of any fleet ’s operat ional manual and
should be done by t he t echnicians w henever t he vehicle is brought in for regular
prevent ive maint enance.
15. General Visual Inspect ion.
Summary: General visual inspect ion of cylinder is done for signs of

ext ernal damage Or abuse. These inspect ions should be
done as a part of normal prevent ive maint enance or ot her
regularly scheduled act ivit y.
Performed by: Ow ner / Operat or
Removal of Cylinder: No
Removal of shielding: No (Opt ional)
Frequency: The follow ing recommendat ions should be follow ed
• Performed during any vehicle maint enance
• Performed at mont hly int ervals by refueling or service personnel.
M et hodology: The general visual inspect ion cont ains t w o st eps as follow s:
General Visual Inspection
Step 1 (Inspection) Step 2 (Disposition)

Step 1. Inspection
If t he vehicle is not on a lift and cylinders are m ount ed underneat h, use a creeper or
jack t o access cylinders
If cylinders are roof mount ed open roof mount ed shields
Examine each cylinder t o ensure t hat each cylinder is securely at t ached t o t he vehicle
Examine each cylinder for signs of gross damage.
Not e: If cylinders are shielded check shields for signs of damage. If shields are damaged,
perform a det ail visual inspect ion by rem oving t he shield. If cylinder is damaged go in for
re-qualificat ion procedure.
Step 2. Disposition
If rubber gasket s / mount ing st raps are loose or not in place or t here is rot at ion of
cylinder st raining t he piping t hen loosen t he mount ing bracket s, reposit ion t he gasket s
and re-t orque bolt s.
Check for damage t o mount ing bracket s. If damaged, check if cylinder is damaged by
[performing det ailed visual inspect ion. If cylinder is not damaged, obt ain new bracket s
and remount t he cylinders.
If cylinder gas heat damage, t hen perform det ailed visual inspect ion and classify damage
as per sect ion * * * * * * * * * * * *
If t here is apparent impact damage t o t he cylinder, perform a det ailed visual inspect ion
and classify damage as per sect ion * * * * * * * * * * * * * *
If t here is abrasion damage perform a det ailed visual inspect ion and classify damage
according t o * * * * * * * * * * *
If t here is damage t o t he PRD, perform a det ailed visual inspect ion and classify damage
according t o * * * * * * * *
If t here is damage t o t he valve, perform a det ailed visual inspect ion and classify damage
according t o sect ion * * * * * * * * * *
16. Det ailed Visual Inspect ion
Summary: The det ailed visual inspect ion is a t hrough visual

inspect ion of t he cylinder and bracket assembly by a
qualified and t rained t echnician.
Performed by: Trained and experienced t hird part y or t rained in-house

individual.
Removal if Cylinder: No.
Removal of Shield: Yes
Frequency: Every 3 years or 36000 K.M (Which ever comes earlier)
Tools: High int ensit y light , angled inspect ion mirrors, hand t ools,
t orque w rench, dept h gauge, ruler, leak t est fluid,
M et hodology: The det ailed visual inspect ion cont ains t he follow ing st eps:
General Installation
Inspection
Step 1
Preparation
Mounting Bracket
Inspection
Step 2 PRD Inspection

Inspection
Piping Inspection
Step 3
Disposition Cylinder Inspection
St ep 1: Preparat ion
If cylinders are mount ed underneat h vehicle, lift t he vehicle using a hydraulic lift
If cylinders are roof mount ed, open roof mount ed shields
If cylinders are mount ed in t he t ruck bed and are shielded, remove shields.
Clean cylinders w it h soap and w at er solut ion w it h a clot h
Not e cylinder / vehicle det ails like serial number, dat e of manufact uring, vehicle number
Et c
St ep 2. Inspect ion: General Inst allat ion Guidelines
Verify t hat an appropriat e label is on t he cylinder and t hat t he cylinder is being properly
Used t o st ore CNG only at t he rat ed pressure
Verify t hat t he cylinder service as defined by t he manufact ure life has not expired. If
expired condemn cylinder
Ensure cylinders are prot ect ed from road debris and ot her forms of pot ent ial damage.
St ep 2. Inspect ion: M ount ing Bracket Inspect ion
Inspect each cylinder bracket for proper mount ing t o vehicle body. Check t hat fast eners
or locknut s are t ight and look for signs of cylinder movement
Verify t hat rubber gasket s are in place and are in good condit ion. Verify t hat t he
bracket s are in good condit ion. Check bracket t o vehicle mount ing for signs of damage
or st ress (bent sheet met al or fract ures)
St ep 2: Inspect ion: PRD inspect ion
Verify t hat PRD is properly at t ached t o t he cylinder valve. If no PRD is present , cont act
valve manufact urer or t heir local sales agent .
Examine t he valve and PRD assembly for damage. Damaged valve and PRD assemblies
must be replaced out right . Inspect t he PRD device for signs of bulging of t he t hermally
act ive mat erial. This can be performed by rubbing fingers over PRD at t he t hermal
t rigger.
Follow ing are t he general guidelines for PRD inspect ion. The inspect or shall review t he
PRD manufact urer’s recommendat ions t o det ermine t he act ions for accept ance /
replacement of t he PRD
Type of Damage Recommendat ions

Creeping of fusible mat erial PRD Should be replaced
Fat igue cracking of pressure burst Disk PRD Should be replaced
St ress corrosion cracking of Brass Body PRD Should be replaced
Freezing w at erline damage PRD Should be replaced
Not e. 1. At t he t ime of periodic visual inspect ion replace t he PRD w it h a new one.
2. Component s of PRD shall be reassembled, reinst alled in accordance w it h t he

Recommendat ions of t he valve manufact urer
St ep 2: Inspect ion: Piping and Hose inspect ion
Inspect t ubing for leaks (w it h soap and w at er solut ion), damage, w ear and signs of
det eriorat ion or corrosion.
Inspect hoses for leaks, damage, w ear, and signs of det eriorat ion and corrosion. Ensure
loses are rat ed for CNG use, marked w it h manufact urer’s name or t rademark and
marked w it h rat ed pressure.
St ep 2: Inspect ion: General Cylinder Inspect ion
Perform det ailed visual inspect ion st art ing at fill end and going t o t he opposit e end. Use
a flashlight , high int ensit y light and mirror t o aid inspect ion.
If cut s, scrat ches or abrasions are visible measure t he dept h and lengt h of t he cut s and
scrat ches using a dept h gauge or calipers and rulers or ult rasonic t hickness t est er. Not e
t he dept h and lengt h on t he visual inspect ion dat a sheet .
St ep 3: Disposit ion
Aft er t he visual inspect ion and damage areas should be classified. The follow ing st eps
should be used t o classify t he damage:
St art
Classify
Damage as
per Table *
Level 1 Level 2 Level 3

Instructions Instructions Instructions
The follow ing guidelines should be follow ed for disposit ion of cylinders
Level Of Damage Disposit ion

Level 1 Cylinder approved for cont inued use
Level 2 The cylinder should be handled according

t o cylinder manufact ures guidelines
Level 3 Cylinder must be condemned and

dest royed.
At t he complet ion of inspect ion, cylinders t hat are approved for cont inued use should
have a st icker or not ificat ion placed on t he cylinder or vehicle indicat ing t he dat e and
t he ident ificat ion of t he inspect or. Condem ned cylinders should be marked and
dest royed.
Levels Of Damage
The follow ing Guidelines should be follow ed for disposit ion of cylinders. Refer t he t able
below :
Level Of Damage Disposit ion

Level 1 Damage is minor and less t han 0.25 mm in
dept h. Such damage should have no
adverse effect s on t he safety of t he
cylinder and it s cont inued use. Damages
such as scrat ched paint , nicks or dings t hat
have no appreciable dept h are considered
t o be in t his cat egory.
Level 2 Damage great er t han or equal t o 0.25mm

in dept h. Suck kind of damage is more
serious t han level 1 and should be given
more at t ent ion. Such kind of damage can
be repaired and t he cylinder ret urned t o
service based on t he recommendat ions
given in t able 3. All such cylinders should
be properly repaint ed aft er carrying out
t he repair w ork before put t ing int o re-
service.
Level 3 All cylinders w hich are beyond repair as

recommended in t able 3 shall be reject ed
and condemned. Under any circumst ances
cylinders w hose minim um w all t hickness is
less t han t he specified minimum design
w all t hickness shall be ret urned t o service.
17. Classificat ion of Visual Damage.
Type of Damage Repair – Recommendat ions / Solut ions
Cut / Scrat ches / gouges A cut or scrat ch may occur on a met al
cylinder w hen it is hit by a shard edged
object .
It is a sharp impression on t he cylinder w all
w here t he mat erial is removed.
If cut , scrat ches, gouges are in t he range of
0.25 mm t o 0.5 mm, repair it by rounding
off t he sharp edges by using hand
operat ed pow er t ool. Great care should be
t aken t o avoid int roducing new defect s t o
t he affect ed area. Aft er such a repair job
t he cylinder should be re-examined t o
ensure t hat t he w all t hickness has not
reduced below minimum specified w all
t hickness. The affect ed area should be
repaint ed.
Abrasion. Abrasion may be due t o some met allic

object cont inuously rubbing against t he
cylinder. It may be due t o poor inst allat ion
or bad road condit ions.
M et al cylinder show ing evidence of
abrasion shall be closely examined t o
verify t he amount of met al rem oved. If t he
dept h is great er t han 0.5 mm and has
reduced t he w all t hickness t o less t han t he
minimum design t hickness t hen condemn
t he cylinder.
If t he t hickness has not reduced below t he

specified minimum design w all t hickness
t hen prepare t he surface for repaint ing.
Use bonded abrasives mount ed point s of
suit able shape and size for rounding off
t he edges.
Use ext reme care so as not t o int roduce
new injurious defect s.
If t he cylinders are exposed t o sunlight or

Charring / Soot if it is under any chemical effect ,
blackening or brow ning of t he affect ed
area may occur. Repaint t he affect ed area.
Chemical At t ack When a cylinder is subject ed or exposed t o

acidic chemicals it s surface may get
corroded or it may get dissolved. M et al
cylinders exhibit pit t ing, corrosion and
oxidat ion due t o prolonged exposure t o
moist ure, aut omot ive fluids or corrosive
agent s. Under such cases w ash off t he
chemicals t horoughly and examine t he
cylinder for evidence of chem ical effect .
Examine t he cylinder for discolorat ion and
mat erial loss.
If t here is no effect , cont inue using t he

cylinder. For minor discolorat ion repaint
t he cylinder. If t he cylinder suffers from
pit t ing and corrosion examine t he w all
t hickness. If it is st ill more t han t he
minimum design t hickness use appropriat e
abrasive paper t o remove t he corrosion
marks and repaint t he cylinder.
Dent A depression may occur if t he cylinder is

hit by an object at high velocit y.
M inor dent of 0.5mm dept h shall be

rounded off by a manually operat ed pow er
driven fine grit mount ed w heel. This w ill
reduce t he st resses in t he cylinder and
improve safet y.
Aft er such a repair cylinder should be re-

examined t o ensure t hat w all t hickness is
not reduced below t he specified minimum
design w all t hickness. Prepare t he surface
and repaint t he cylinder.
Weat hering Cylinder surface may get affect ed by

ult raviolet radiat ion from sunlight .
Degradat ion of ext ernal coat ing may lead

t o met al surface corrosion. The affect ed
area may by cured by applicat ion of fresh
coat ing.
General Corrosion, Pit s, It is an area of mat erial loss due t o

corrosion lines chemical oxidat ion or rust ing.
Light corrosion can be cleaned and t he

affect ed area repaint ed.
For heavy corrosion great er t han 0.5 mm

in dept h t he affect ed area should be
reexamined t o ensure t hat t he w all
t hickness has not reduced below t he
specified minimum design w all t hickness. If
t he w all t hickness is more t han t he
minimum design t hickness Use
appropriat e abrasive paper t o remove
corrosion marks and repaint t he cylinder.
If t he w all t hickness has been reduced t o

less t han t he minimum design t hickness
condemn t he cylinder
18. Cylinder Dest ruct ion
Cylinders t hat are condemned must be removed form service and dest royed in a safe
manner. Cylinders should be dest royed in such a manner t hat t hey are rendered
unusable and cannot be repaired in any w ay.
Before cylinders are condemned t hey should be checked for any residual gas. Even if t he
cylinders appear t o be empt y some small amount of gas w ill alw ays be present . This gas
must be complet ely removed and purged.
Refer sect ion 10.0 t o safely vent ing procedure. Cylinders should not be vent ed w it hout
proper elect rical grounding.
The follow ing st eps / procedure should be follow ed:
1) Remove and purge t he residual gas form t he cylinder
2) Remove valves and ot her fit t ings (if any).
3) Erase t he cylinder markings w it h a hand operat ed pow er t ool. The markings

should be rendered unreadable.
4) Drill a hole or cut t he cylinder in half.
5) Scrap t he cylinder.
19. Hydrost at ic t est ing.
Hydrost at ic t est ing is a t est performed on high pressure gas cylinders t o check for leaks
or flaw s and should be done every 5 years or at t he frequency defined by t he regulat ory
aut horit y in t he specific count ry.
Hydrost at ic t est involves filling t he cylinder w it h a nearly incom pressible liquid - usually
w at er or oil - and examined for leaks or permanent changes in shape. Red or fluorescent
dyes are usually added t o t he w at er t o make leaks easier t o see. The t est pressure is
alw ays considerably more t han t he operat ing pressure t o give a margin for safet y,
t ypically 150% of t he design pressure. Wat er is commonly used because it is almost
incompressible (compressible only by w eight , not air pressure), so w ill only expand by a
very small amount should t he vessel split . If high pressure gas w ere used, t hen t he gas
w ould expand t o perhaps several hundred t imes it s compressed volume in an explosion,
w it h t he at t endant risk of damage or injury.
Cylinders are normally t est ed using a w at er jacket t est . The cylinder is visually examined
for defect s and t hen placed in a cont ainer filled w it h w at er, and in w hich t he change in
volume of t he vessel can be measured by monit oring t he w at er level. For best accuracy
a digit al scale is used t o measure t he smallest amount s of change. The vessel is t hen
pressurized for a specified period usually 30 or more seconds and depressurized again.
The w at er level in t he jacket is t hen examined. The level w ill be great er if t he cylinder
being t est ed has been dist ort ed by t he pressure change and did not ret urn t o it s original
volume or some of t he pressurized w at er inside has leaked out . In bot h cases, t his w ill
normally signify t hat t he cylinder has failed t he t est .
Aft er t he t est is carried out t he informat ion such as dat e of t est ing and t he next t est
dat e is st amped on t he cylinder. The cylinder serial number and ot her st amped dat a
should be recorded and properly maint ained for fut ure t est ing and reference all t hrough
t he cylinder service life.
20. Acoust ic Em ission Test ing
Generally acoust ic emission t est ing is not required for t est ing NGV cylinders. This t est
can be used t o supplement visual inspect ion t est ing.
Acoust ic emissions are st ress w aves t hat are generat ed by mat erials w hen t hey are
st resses. Sensors mount ed on t he surface of t he cylinder can pick up t hese st ress w aves.
Damaged or degraded area of t he cylinder emit s more of t hese st ress w aves t han an
undamaged port ion.
For inspect ion of CNG cylinders, t he sensors are at t ached t o t he surface of t he cylinder
and t he cylinder is refueled. Acoust ic measurem ent s are t aken during t his refueling. A
damaged cylinder w ill emit more act ivit y t han an undamaged cylinder and t he sensors
w ill pick such emissions.
The major advant ages of acoust ic emission t est ing are:
1) It does not require removal of t he cylinder form t he vehicle.

2) This t est can det ect any int ernal damage in t he cylinder.
The major draw back of t he t est is t hat it requires t rained personnel t o conduct and
int erpret t he t est result s. The acoust ic emission t est also t akes longer t o conduct t han a
t ypical visual inspect ion.
Not e. The acoust ic emission t est is not a subst it ut e for a visual inspect ion t est .
21. Types of Cylinder Damage
This sect ion is t o provide t he user w it h a det ailed descript ion of t ypes of damages t hat
can be inflict ed t o a CNG Cylinder and t he st eps t hat are t o be t aken as per t he t ype of
damage incurred. This sect ion also includes w ays t o prevent such t ypes of damage from
occurring.
Types of Cylinder Damage

Type of Damage Section
Surface corrosion 22
Fatigue Cracks 23
Impact Damage 24
Stress Corrosion 25
Fire or heat Damage 26
22. Surface corrosion
Surface corrosion on st eel can produce rust ing or pit t ing. This surface corrosion can
reduce t he cylinder w all t hickness, w hich if left unt reat ed could result in w eakening of
t he cylinder or failure. A lack of rubber gasket s under bracket s can cause accelerat ion of
t he corrosion. There fore rubber gasket s are a must and should alw ays be used.
Solut ion: Alw ays ensure cylinders are paint ed. Light corrosion can be cleaned and
cylinders repaint ed. For heavy corrosion and pit t ing, t he approximat e dept h of t he
pit t ing should be det ermined and t he cylinder should be removed from service if t he
dept h of t he corrosion or pit t ing exceeds more t he .5 mm and reduces t he minimum
design t hickness.
23. Fatigue Cracks
Any t ype of met al cont ainer such as a high pressure CNG cylinder w ill suffer from
Fat igue cracking if it is subject ed t o a large number of pressure cycles. This t ype of
fat igue generally st art s from t he int erior of t he cylinder.
NGV cylinders are designed so t hat fat igue cracking should not occur during t he
expect ed service life of t he cylinder. Cylinders should not be used beyond t heir service
life. The expect ed service life durat ion of t he cylinder is marked on t he cylinder.
24. impact Damage
If impact damage is suspect ed, t he cylinder should be carefully examined using t he

det ailed visual inspect ion procedure. The area of great est concern is t he neck and
bot t om of t he cylinder. Impact damage may also occur w hen cylinders are dropped
during handling. Ext reme care should be t aken w hen cylinders are being moved.
Damage can also occur from road debris and for t his reason undercarriage mount ed
cylinder should be properly shielded.
25. Stress Corrosion
St ress corrosion can occur w hen t he cylinder comes in cont act w it h a corrosive liquid.
Acids such as bat t ery acid are one of t he most corrosive agent s. St ress corrosion can
also happen w hen cylinders come int o cont act w it h very st rong bases. For t his reason
bat t eries should never be t ransport ed in t he bed of pick-up t ruck or locat ed near t he
cylinders.
26. Fire and Heat Damage.
Fire and heat damage can occur in all t ypes of cylinders. If a vehicle has been involved in
a fire, t hen t he cylinders should be rem oved and condemned. A more common form of
damage is heat damage w hen t he cylinder is t oo close t o a heat source such as an
exhaust pipe. Even t hough st eel cylinders are less suscept ible t o such damage st ill t hey
should be inst alled at some dist ance form t he vehicle exhaust system, especially in
undercarriage inst allat ions.
A minimum dist ance of 8 inches should be alw ays maint ained. And cylinders t hat are
close t o a heat source should have heat shields.
27. Prot ect ion and inspect ion of PRD and cylinder valves
Pressure relief devices (PRD) are essent ial part of an NGV cylinder fuel st orage system.
The main job of a PRD is mainly t o release t he nat ural gas from t he cylinder in t he event
of fire. The PRD in case of fire prevent s t he build-up of pressure w it hin t he cylinder
w hich can lead t o cylinder w all rupt ure and event ual failure of t he cylinder.
Gas pressure significant ly increases w hen a closed cylinder is heat ed as in case of fire.
There are t hree t ypes of PRDs:
1) Thermally Act ivat ed: These devices are act ivat ed only by high t emperat ures.
This t ype of device generally cont ains a fusible mat erial
t hat can melt at a cert ain t emperat ure. When t his occurs,
t he met ing of t he fusible mat erial opens up a pat h for
nat ural gas t o release t hrough a vent hole.
Almost all PRDs in use t oday are of t his t ype.
2) Series Combinat ion: These devices are act ivat ed by high t emperat ure and high
Pressure. This design generally has a fusible mat erial t hat
Is backed by a pressure burst disk.
3) Parallel Combinat ion: These devises are act ivat ed by eit her high t emperat ure or
High pressure. The design generally has t w o vent pat hs,
One is prot ect ed by a fusible mat erial and t he ot her by a
Pressure burst disk.
A PRD device can suffer form t he follow ing problems:
1) Creeping of t he fusible mat erial

2) Fat igue cracking of t he pressure burst disk
3) St ress corrosion cracking of brass body of PRD
4) Freezing w at er in t he vent line damaging t he PRD.
PRD vent lines should have a cap t o prevent w at er from filling t he vent lines. Periodic
visual inspect ion is needed t o make sure t his cap is in place and t hat w at er or ot her
ext ernal debris has not filled t he vent lines.
During rout ine visual inspect ion if creeping, bulging and hairline cracks are observed,
t he PRD should be immediat ely replaced. Alw ays remember PRD cannot be repaired.
Replacement is t he only recommended course of act ion in such scenario.
Pict ure of a t ypical Pressure Relief Device
28. Handling and Storage of Cylinders.
Improper Handling and st orage of High Pressure gas cylinders have been report ed as
immediat e causes of numerous incident s result ing in injuries and propert y damage.
Because of t heir pot ent ial t o cause incident s / accident s, t he follow ing rules for handling
cylinders must be adhered t o:
• Never drag, slide, or drop cylinders.

• Do not lift or move cylinders using the cylinder valve as leverage
• Transport cylinders in an upright position using a cart designed for that purpose.
• If forklifts are used to lift cylinders, take extra precaution as the forks can inflict damage
to the cylinders.
• If cylinders are stacked, make sure the stacks are stable, if not the cylinders may roll /
fall and injure personnel
• Prot ect cylinders from cont act w it h ground, ice, snow , w at er, salt , corrosion, and
high t emperat ures.
• Alw ays place cylinders in a locat ion w here t hey w ill not be subject ed t o
mechanical or physical damage and excessive heat .
• It is good pract ice t o w ear safet y shoes and gloves w hen moving cylinders
Improper W ay of Storing Cylinders, A steel or wooden stopper should be used to prevent

cylinders from rolling off storage
The proper packaging / storing of cylinders for extended periods.
Cylinders should not be handled by Valve / PRD
Loading and unloading of cylinders with a forklift.

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EKC International FZE

Safety Instructions for

1.0 Compressed nat ural Gas (CNG)

3. Compressed Natural Gas (CNG) Cylinders for Natural Gas Vehicles

4. Terms and Definitions

All met al Cylinder : A cylinder t hat is made from met al only

Level 1 Damage : M inor damage t hat is considered normal and

Type 3 : Classificat ion for cylinder t hat is const ruct ed from a

5. Sensitivity of cylinder materials to operating conditions and solutions

M at erial Possible Damage Solut ion

Impact Damage Ensure Cylinders are

Fire / Heat damage Ensure Cylinders are not

Chemical Attack Avoid exposure to harsh

Abrasion Abrasion may occur due to

Proper care should be t aken w hen m ount ing cylinders

• Prevent abrading, minimize and w it hst and vibrat ions.

Flimsy home made

Example of a poor Cylinder Installation.

Cylinder Shielding should be used t o prot ect t he cylinder.

• Damage from road Debris

It is not recommended / advised t o remove cylinders from t he vehicles except in t he

• If vehicle has been involved in an accident or fire

• Cylinders should not be dropped

In t w o cases cylinders must be defueled (Depressurized)

Emergency defueling must be performed w hen vehicle is involved in an accident

A scheduled defueling is planned removal of CNG from t he cylinder w hich may be

10. Atmospheric Venting Equipment.

General Atmospheric Venting Equipment

A schemat ic diagram of a t ypical vent ing syst em is show n above.

The syst em w ill also include t he follow ing equipm ent .

In addit ion t o t he above it ems, it is recommended t o keep t he follow ing safet y

If t he cylinder is not mount ed on a vehicle it should be properly rest rained as it may

11. Emergency Defueling Procedure t o At mosphere

The general procedure for emergency defueling is as follow s:

12. Scheduled Defueling Procedure.

Scheduled defueling is t he preferred met hod of depressurizing cylinders. In t his process

13. Cylinder Inspect ion.

Inspect ion Descript ion Removal of Cylinder Frequency

Hydrost at ic Required by vehicle Yes 5 years for Type 1

Acoust ic Em ission Non Dest ruct ive No M ay be performed

14. Guidelines for Visual inspect ion.

Visual inspect ion can be carried in t w o w ays.

• Periodic General Inspect ion

• Periodic Det ailed Visual inspect ion

Element s of Visual Inspect ion

15. General Visual Inspect ion.

Summary: General visual inspect ion of cylinder is done for signs of

Performed by: Ow ner / Operat or

Removal of shielding: No (Opt ional)

Frequency: The follow ing recommendat ions should be follow ed

• Performed during any vehicle maint enance

• Performed at mont hly int ervals by refueling or service personnel.

General Visual Inspection

Step 1 (Inspection) Step 2 (Disposition)

If cylinders are roof mount ed open roof mount ed shields

Examine each cylinder for signs of gross damage.

16. Det ailed Visual Inspect ion

Summary: The det ailed visual inspect ion is a t hrough visual

Performed by: Trained and experienced t hird part y or t rained in-house

Removal if Cylinder: No.

Removal of Shield: Yes

Frequency: Every 3 years or 36000 K.M (Which ever comes earlier)

Step 2 PRD Inspection