CODE OF PRACTICE FOR USE OF CNG /Bio- CNG/LNG FUEL IN .
Draft AIS-024 (Version 5)/F/Aug. 2016Finalized DraftAIS-024SAFETY AND PROCEDURAL REQUIREMENTSFOR TYPE APPROVAL OFCNG/Bio-CNG/LNG OPERATED VEHICLES(DEDICATED, BI-FUEL & DUAL FUEL)(Version 5)ANDAIS-028CODE OF PRACTICE FOR USE OF CNG/BioCNG/LNG FUEL IN INTERNAL COMBUSTIONENGINED VEHICLES(Version 5)Date of hosting on website: --------Last date for comments :------------I
Draft AIS-024 (Version 5)/F/Aug. 2016CHECK LIST FOR PREPARING REVISION TOAUTOMOTIVE INDUSTRY STANDARD (AIS)AIS-024 (Version 5): Safety and Procedural requirements for Type Approvalof CNG/Bio-CNG/LNG operated vehicles (Dedicated,Bi-Fuel & Dual Fuel)AIS-028 (Version 5):SR.NO.11.12345Code of practice for use of CNG/Bio-CNG/LNG fuel inInternal Combustion Engined VehiclesPARTICULARSREMARKSIndicate details of the base reference standard.(e.g. ECE/ EEC directive/GTR, etc )AIS-024 and AIS-028Latest version of the base standard (Sr. No.1)considered for the alignment of this standard.Add an explanatory note indicating differencesbetween the above standard and this standard,if any.Version 5Addition of Bio-CNG andLNG technology in AIS-024andAIS-028Are the details of technical specifications to be Yessubmitted at the time of type approval relevantto the requirements of this standard covered?Are the performance requirements covered?YesIs there a need to specify dimensional Yesrequirements? If yes, are they covered?6Are the details of Criteria for Extension of NAType Approval covered?7Is AIS-037 applicable for the devices covered Yes, for CNG/Bio-CNG/LNGin this standard, If yes:Regulators it is covered inAIS-037Is there a need to specify COP requirements?Yes, for CNG/Bio-CNG/LNGIf yes, are following covered?Regulators it is covered inAIS-037Tests/checks needed for COPYes, for CNG/Bio-CNG/LNGRegulators it is covered inAIS-037Periodicity of COPYes, for CNG/Bio-CNG/LNGRegulators it is covered inAIS-037Have the transitional provisions for extension NAof AIS-037 approval been covered?7.17.27.37.47.5Has the “type” been defined?YesII
Draft AIS-024 (Version 5)/F/Aug. 20168.Is this standard covers the requirements of E/e Yesapproved components?9.Are the provisions for further amendments in As applicable as per AIS-000ECE regulations addressed?10.Is the standard is intended for replacing or AIS-024 (Version 4)revising an already notified standard, if yes:AIS-028 (Version 4)10.1AretheTransitionalprovisionsfor As applicable as per icles by comparing the previous testresult, certain additional test, etc. covered?10.2Can this standard be permitted in lieu of the Yesexisting notified standard from the date ofadoption of this standard by CMVR TSC?10.2.1If so has this been included in the transitional As applicable as per AIS-000provisions10.3Have all the transitional provisions been As applicable as per AIS-000covered?11.Status of availability of test facilities with Availableapproved test agencies?12.Are there any points on which special Nocomments or information is to be invited frommembers?If yes, are they identified?13.Do components / vehicles manufacturers / Test Yes six monthsagencies require lead time to meetrequirements of revision?13.1Recommendation of date for implementation With the lead time of sixof revision.Month from date of notifiction14.Is proposed draft notification prepared?15Has the clarityexamined?16Has the clarity of definitions been examined?ofclassificationIIIYesbeen YesYes
Draft AIS-024 (Version 5)/F/Aug. 2016AMENDMENT RECORDThis document contains AIS-024 and AIS-028Version 1Effective from 21st May 2001 Discontinued from 12th July2001Version 2Effective from 12th July 2001Version 3Effective from 26th February 2002Version 4Effective from August 2015Version 5Effective from 2016III
Draft AIS-024 (Version 5)/F/Aug. 2016CONTENTSSr.DocumentNo.1.AIS-024 (Version 4)DescriptionSafety and procedural requirements for typeapproval of CNG/Bio-CNG/LNG operatedvehiclesPageNo.1/892.Annexure ITechnical specificationCNG/LNG kitofCNG/Bio-3/893.Annexure IITechnical specificationCNG/LNG vehiclesofCNG/Bio-8/894.Annexure IIIChecklist for fitness tests and certificationfor in-use vehicles after fitment / conversionto CNG/Bio-CNG/LNG mode11/895.Annexure IVSafety checks for use of CNG/BioCNG/LNG fuels in internal combustionengined vehicles (as per AIS-028) & Indiangas cylinder rules, 200412/896.Annexure VCriteria to authorize the CNG/BioCNG/LNG kit installer and responsibility ofvehicle / kit manufacturer / supplier /installer15/897.Annexure VIInstallation certificate for converted CNG/Bio-CNG/LNG vehicle18/898.Annexure VIIChecklist for third party checking orinspection of built-up CNG/Bio-CNG/LNGbuses (New and In-use) before registration20/899.Annexure VIIIChecklist for preventive maintenance ofin-use CNG/Bio-CNG/LNG vehicles29/8910.Annexure IXChecklist for third party checking /inspection of CNG/Bio-CNG/LNG vehicles(other than CNG/Bio-CNG/LNG buses)before registration (New and In-use)35/8911.Annexure XTests to be carried out by Test CNG/BioCNG/LNG Fitment47/8912.AIS-028 (Version 4)Code of practice for use of CNG/BioCNG/LNG fuel in internal combustionengined vehicles50/8913.Annexure XIAISC Panel Composition88/8914.Annexure XIIAutomotiveIndustryCommittee CompositionIIIStandards89/89
Draft AIS-024 (Version 5)/F/Aug. 2016INTRODUCTIONThe Government of India felt the need for a permanent agency to expedite thepublication of standards and development of test facilities in parallel when thework on the preparation of the standards is going on, as the development ofimproved safety critical parts can be undertaken only after the publication of thestandard and commissioning of test facilities. To this end, the erstwhile Ministry ofSurface Transport (MOST) has constituted a permanent Automotive IndustryStandards Committee (AISC) vide order No. RT-11028/11/97-MVL datedSeptember 15, 1997. The standards prepared by AISC will be approved by thepermanent CMVR Technical Standing Committee (CMVR-TSC). After approval,the Automotive Research Association of India, (ARAI), Pune, being the Secretariatof the AIS Committee, will publish this standard. For better dissemination of thisinformation ARAI may publish this document on their Web site.Version 5 of AIS-024 and AIS-028 is prepared to include safety and proceduralrequirements for type approval of CNG/Bio-CNG/LNG (Dedicated HCV Vehiclesonly) operated vehicles using Dual Fuel technology in addition to Dedicated andBi-Fuel technology. It may be noted that Liquefied Natural Gas (LNG) shall bepermitted for OE manufactured Vehicles having GVW 3.5 T.The AISC panel responsible for formulation of this standard is given in Annex XI.The Automotive Industry Standards Committee (AISC) responsible for approval ofthis standard is given in Annex XII (To be included).III
Draft AIS-024 (Version 5)/F/Aug. 2016SAFETY AND PROCEDURAL REQUIREMENTS FOR TYPE APPROVAL OFCNG/Bio-CNG/LNG OPERATED VEHICLES (DEDICATED, BI-FUEL & DUALFUEL)For CNG/BioCNG/LNG** Fitmentby OE Manufacturerfor New VehicleFor Retrofitment ofIn-Use Vehicle(CNG/Bio-CNG/LNGDual Fuel Engine)For Replacement ofIn-Use Diesel Engine byNew CNG/Bio-CNG/LNGEngineDocuments to be Specification of CNG/ Specification of CNG/ Specification of CNG /submittedBio-CNG/LNG kit in Bio-CNG/LNG kit as per Bio-CNG/LNG kit as perthe given format as per Annexure I.Annexure I.Annexure I.Detailed and brief Technical specification oftechnical specifications the retrofitted vehicle asof vehicle in AISC per Annexure II.format (AIS-007).Details of alterationscarried out on dieselengine to CNG / BioCNG/LNG along withnames of the supplier.CMVR ChecksCMVR checks / testsare to be conducted byTest Agency as perCMVR No. 93 to 125.Certificates of originalpetrol/dieselenginedvehicles to be producedforcheckingcompliance of as manycommonrulesofCMVR for petrol/diesel vehicle andCNG/ Bio-CNG/LNGvehicle.Whichever rules are notcomplied with becauseof changes made forconversion, the sameare to be re-checked asper applicable CMVR.PerformanceTests as perCMVRTechnical specifications ofin-use diesel vehicle as perAnnexure II.Technical specification ofvehicle and CNG / BioCNG/LNG engine as perTable 2 and 4 ofAIS-007.Undertaking by the kitmanufacturer/supplierregarding fitness (as perAnnexure III) and fitnesscompliance as per CMVRas amended by theGovernment of India fromtime to time, of the in-usevehicle to be submitted tothe test agency for theexaminationandevaluationbeforeundertaking performancetests on CNG/ BioCNG/LNGfuelledvehicles.Undertaking by the vehiclemanufacturer/kitmanufacturer/ kit supplierregarding fitness (as perAnnexure III) and fitnesscompliance as per CMVRas amended by theGovernment of India fromtime to time, of the in-usevehicle to be submitted tothe test agency for theexamination and evaluationbeforeundertakingperformance test on CNG/Bio-CNG/LNGfuelledvehicles.Assessment of structuralintegrity in case of heavypassenger/goodsdieselvehicles to be provided bythe retrofitter or kitinstaller.Assessment of structuralintegrity in case of heavypassenger/goodsdieselvehicles to be provided bythe retrofitter or kitinstaller.As per Annexure X-a As per Annexure X-b of As per Annexure X-c ofof AIS-024*.AIS-024*.AIS- 024*.1/93
Draft AIS-024 (Version 5)/F/Aug. 2016Safety Checksas per AIS-028.As given in Annexure As given in Annexure IV As given in Annexure IVof AIS-024*.of AIS-024*.IV of ibility ofthe vehicle / kitmanufacturer /supplier/installer-As given in Annexure V As given in Annexure V ofof AIS-024*.AIS-024*.Formatof As per Annexure VI of As per Annexure VI of As per Annexure VI teforconverted CNG/Bio-CNG/LNGvehicleChecklistfor As per Annexure VII of thirdparty AIS-024*.checkingorinspectionofbuilt-up CNG/Bio-CNG/LNGbusesbeforeregistrationChecklistfor preventivemaintenance ofin-useCNG/Bio-CNG/LNGvehicles-As per Annexure VIII of As per Annexure VIII ofAIS-024*.AIS-024*.*As amended from time to time** It may be noted that Liquefied Natural Gas (LNG) shall be permitted for OEmanufactured dedicated LNG Vehicles having GVW 3.5 T.2/93
Draft AIS-024 (Version 5)/F/Aug. 2016ANNEXURE ITECHNICAL SPECIFICATION OF CNG/ Bio-CNG/LNG CONVERSIONKIT (DEDICATED, BI-FUEL & DUAL FUEL)*1. Details of Kit Manufacturer / Supplier / Installera)b)c)d)Name of the ManufacturerAddressTelephone No. & Fax No.Contact person2. CNG /Bio-CNG/LNG Kit Identificationa) Identification No.b) Variants, if any3. CNG/Bio-CNG/LNG Cylinder (PESOapproved/endorsed)a)b)c)d)e)f)g)Name of manufacturerIdentification No.TypeWorking pressure (kg/cm2 ) /(MPa)2Max. test pressure (kg/cm ) /(MPa)Cylinder capacity (water equivalent)Approval reference from PESO4. Cylinder Valve(s) (PESO approved/endorsed)a)b)c)d)e)f)Name of manufacturerModel name/Identification No.TypeWorking pressure (kg/cm2 ) /(MPa)2Max. test pressure (kg/cm ) /(MPa)Approval reference from PESO5. CNG/Bio-CNG/LNG Solenoid Valvea)b)c)d)e)Name of manufacturerModel Name/Identification No.Type2Working pressure (kg/cm ) /(MPa)2Max test pressure (kg/cm ) /(MPa)6. Petrol Solenoid Valvea)b)c)d)e)Name of manufacturerModel Name/Identification No.TypeWorking pressure (kg/cm2 ) /(MPa)Max test pressure (kg/cm2 ) /(MPa)Test atureNameDesignationDateDocument No. (indicating also revisionstatus)Sheet No.--------of--------3/93
Draft AIS-024 (Version 5)/F/Aug. 20167. Refilling valvea)b)c)d)e)Name of the manufacturerModel name/Identification No.TypeWorking pressure (kg/cm2 ) /(MPa)2Max test pressure (kg/cm ) /(MPa)8. Pressure Regulator / Vaporizer for LNGa)b)c)d)e)f)Name of manufacturerModel name/Identification No.TypeInlet pressure (kg/cm2 ) /(MPa)Outlet pressure (kg/cm2 ) /(MPa)No. of stages9. CNG/ Bio-CNG/LNG Filtera)b)c)d)e)Name of manufacturerModel name/Identification No.TypeInlet pressure (kg/cm2 ) /(MPa)2Outlet pressure (kg/cm ) /(MPa)10. Oil Pump or Lubrication System, if anya) Name of manufacturerb) Type11. High Pressure Tubinga)b)c)d)e)f)g)Name of manufacturerModel name/Identification No.Type2Working pressure (kg/cm ) /(MPa)Max. test pressure (kg/cm2 ) /(MPa)Outer diameter/Inner DiameterProtection quality (material used)12. Low Pressure Tubinga)b)c)d)e)f)g)Name of manufacturerModel name/Identification No.TypeWorking pressure (kg/cm2 ) /(MPa)2Max test pressure (kg/cm ) /(MPa)Outer diameter/Inner DiameterProtection quality (material used)Test atureNameDesignationDateDocument No. (indicating also revision status)Sheet No.--------of--------4/93
Draft AIS-024 (Version 5)/F/Aug. 201613. Gas-Air Mixera)b)c)d)Name of manufacturerModel name/Identification NoType & drawingVenturi Size14. Gas Injectora)b)c)d)Name of manufacturerModel name/Identification NoType & drawingInjector flow specs15. ON/OFF Switcha) Name of manufacturerb) Model name/Identification Noc) Type16. Ignition System & Wiring Harness (for CNGBio-CNG/LNG system) (Ref. Clause A11 ofTable 2 of AIS 007)a)b)c)d)Name of manufacturerType of Ignition SystemSpark plug gap, mmElectrical circuit diagram /Detail layout17. Interfacing Unita) Name of manufacturerb) Model name/Identification No.c) Type18. Ignition Timing Advancera)b)c)d)Name of manufacturerTypeTiming on CNG/Bio-CNG/LNG modeTiming on baseline fuel.19. Fuel selector switcha) Name of manufacturerb) Model Noc) TypeTest atureNameDesignationDateDocument No. (indicating also revision status)Sheet No.--------of--------5/93
Draft AIS-024 (Version 5)/F/Aug. 201620. Dual fuel actuation mechanism(Mechanical/Electronic)a) Brief description of systemb) Schematic layoutc) Identification of critical componentsB) LNG fuel system operation(Mechanical/Electronic)a) Brief description of systemb) Schematic layoutc) Identification of critical components21. Brief Description of System IncludingDimensional Layout for Cylinder and other kitcomponents installation ventilation details etc.22. Catalytic Converter Make & Model23. Refilling valve interlocking switcha) Name of manufacturerb) Identification No.c) Type24. Current limiting Device (Fuse)a)b)c)d)Name of manufacturerIdentification No.Voltage/current ratingType25. Pressure Indicatora) Name of manufacturerb) Identification No.c) Type26. Service shut off valvea) Name of manufacturerb) Identification No.c) Type27. Compartment/Sub-compartment/Gashousingtighta) Name of manufacturerb) Identification NoTest atureNameDesignationDateDocument No. (indicating also revision status)Sheet No.--------of--------6/93
Draft AIS-024 (Version 5)/F/Aug. 2016c) Type28. Conduita)b)c)d)Name of manufacturerIdentification No.Inner & outer diameterType29. Details of Seat/Upholstery/roof and side lininga) Name of manufacturerb) Model name/Identification No.c) Type30. Details ofnon-moisture retaining hardrubber/equivalent material padding/liningprovided for inner side of the cylindermounting band(s)a) Name of manufacturerb) Identification No.c) Type31. Battery cut off switch(if applicable)(a) Name of manufacturer(b) Identification No.(c) Type32. Any other informationNote: In case of OE fitment, if any of the above information is already covered in theinformation submitted as per AIS- 007, only the reference need be given and it isnot necessary to duplicate the information.* Mention NA wherever not applicableTest atureNameDesignationDateDocument No. (indicating also revision status)Sheet No.--------of--------7/93
Draft AIS-024 (Version 5)/F/Aug. 2016ANNEXURE IITECHNICAL SPECIFICATIONS OF VEHICLES1. Manufacturer’s Name and Address2. Vehicle Dataa)b)c)d)e)ModelTypeYear and Month of ManufactureEngine No.Chassis No.3. Enginea)b)c)d)e)f)g)h)i)j)k)l)m)n)TypeBore x Stroke, mmNo. of CylindersDisplacementCompression RatioMax Engine OutputMax TorqueAir CleanerOil FilterFuel FilterCapacity of Cooling SystemOil Sump CapacityWeight of Engine (Complete)Radiator Frontal Area (Core Area)4. Clutcha) Typeb) Outside Diameter5. Gear Boxa)b)c)d)ModelTypeNo. of GearsGear Ratio1st2nd3rd4th5th6the) Reversef) Front Axleg) Rear AxleTest atureNameDesignationDateDocument No. (indicating also revision status)Sheet No.--------of--------8/93
Draft AIS-024 (Version 5)/F/Aug. 2016h) Ratio6. Steeringa) Steering Wheel Diameterb) Ratio7. Framea) Long Member Size, mmb) Number of Cross Members8. Suspensiona) Springb) Anti-Roll Bar9. Shock Absorber10. Brakea)b)c)d)e)f)Service BrakeFrontRearTotal Braking AreaParking BrakeWheels and Tyres11. Electrical Systema)b)c)d)e)System VoltageBatteryAlternator (Max. Output)TypeWiper Motor12. Fuel Tank13. Dimensionsa)b)c)d)e)f)g)h)Wheel Base, mmOverall Width, mmOverall Length, mmFront Track, mmRear Track, mmMin. Ground Clearance, mmCargo Box DimensionsLoad Body Platform Area14. WeightsTest atureNameDesignationDateDocument No. (indicating also revision status)Sheet No.--------of--------9/93
Draft AIS-024 (Version 5)/F/Aug. 2016a) Maximum GVWb) Maximum Permissible FAWc) Maximum Permissible RAWd) KERB weight with 90% fuel (with sparewheel, tools, etc.)e) Maximum Gradeability in 1st Gear15. Seating CapacityTest atureNameDesignationDateDocument No. (indicating also revision status)Sheet No.--------of--------10/93
Draft AIS-024 (Version 5)/F/Aug. 2016ANNEXURE IIICHECKLIST FOR FITNESS TESTS AND CERTIFICATION FOR IN-USEVEHICLES AFTER FITMENT / CONVERSION TO CNG/Bio-CNG/LNGMODE (DEDICATED, BI-FUEL & DUAL FUEL)*Sr. .20.21.22.23.DescriptionSpark plug /Suppression cap / HTcablesHead lightsOther lightsReflectorsBulbsRear view mirrorsSafety glassHornSilencerSari guard, passenger holdDash board equipmentWindshield WiperExhaust emissionBrakeSpeedometerSteeringSeat BeltSuspension springs, viz.a. No. of leavesb. Size of flat (width and thickness)front and rearTyre, viz.a. Size, ply ratingb. Condition of Tyre (new/remoulded)c. Tread depthLocation of exhaust pipeOverall Dimension, viz.a. Lengthb. Heightc. Widthd. OverhangStructural Integritya. Changes to the chassis/ vehicle bodyVisual inspection of propeller shaft and universal joint to be carried out.* Mention NA wherever not applicableVehicle ModelYear of manufactureVehicle Registration/Identification No:Name of the Kit InstallerSignature with SealNameDesignationDateEngine No.Chassis No.Document No. (indicating also revisionstatus)Sheet No.--------of--------11/89
Draft AIS-024 (Version 5)/F/Aug. 2016Annexure IVSAFETY CHECKS FOR USE OF CNG/ Bio-CNG/LNG FUELS ININTERNAL COMBUSTION ENGINED VEHICLES (AS PER AIS-028) &INDIAN GAS CYLINDER RULES, 2004(as amended from time to time)Sr.No.11.123456Certifying /Verifying AuthorityCNG/Bio-CNG/LNG / KitComponentCylinder*Clause of AIS-028/ Other Rules,Standards, etc.PESO, Nagpur to certify or endorse Gas cylinder rules,in case of foreign make2004of Test agency to verify as per AIS-028 Clause no. 2.3, 2.5onand 2.6 of AIS-028FitmentcylindervehicleCylinder valves*Regulator*/Vaporizer (LNG)PESO, Nagpur to certify or endorsein case of foreign makeTesting of the component as perIS: 15713-2006 or ISO-15500 by testagency. Alternatively, test agency toverify the test certificate or reportconforming to the above standardissuedbyaccreditedtestinglaboratory.LNG regulator and Vaporizer shallmeet requirements of ISO:12613-16and ISO:12614-16 respectivelyIS: 3224 or Gascylinder rules2004IS: 15713-2006 orISO-15500ISO:12613-16 andISO:12614-16respectivelyGas-Air Mixer*Testing of the component as per IS: 15714-2006 orIS :15714-2006 or ISO-15500 by test ISO-15500agency. Alternatively, test agency toverify the test certificate or reportconforming to the above standardissuedbyaccreditedtestinglaboratory.Gas Injector
In-Use Vehicle (CNG /Bio-CNG/LNG Dual Fuel Engine) For Replacement of In-Use Diesel Engine by New CNG/Bio-CNG/LNG Engine . vehicle and CNG / Bio-CNG/LNG engine as per Table 2 and 4 of AIS-007. CMV
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