SAFETY AND PROCEDURAL REQUIREMENTS FOR TYPE
AIS-024 (Version 5): 2016AIS-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)PRINTED BYTHE AUTOMOTIVE RESEARCH ASSOCIATION OF INDIAP.B. NO. 832, PUNE 411 004ON BEHALF OFAUTOMOTIVE INDUSTRY STANDARDS COMMITTEEUNDERCENTRAL MOTOR VEHICLE RULES – TECHNICAL STANDING COMMITTEESET-UP BYMINISTRY OF ROAD TRANSPORT & HIGHWAYS(DEPARTMENT OF ROAD TRANSPORT & HIGHWAYS)GOVERNMENT OF INDIA2016I
AIS-024 (Version 5): 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 Aug 2015Version 5Effective from September 2016II
AIS-024 (Version 5): AIS-024 (Version 5)Safety and procedural requirements fortype approval of CNG/BIO-CNG/LNGoperated vehicles2.Annexure I3.Annexure IITechnical specification of CNG / BIOCNG/LNG kitTechnical specification of vehicles4.Annexure IIIChecklist for fitness tests and certificationfor in-use vehicles after fitment /conversion to CNG / BIO-CNG mode10/965.Annexure IV11/966.Annexure V7.Annexure VI8.Annexure VII9.Annexure VIIISafety checks for use of CNG / BIOCNG/LNG fuels in internal combustionengined vehicles (as per AIS-028) &Indian gas cylinder rules (as amended fromtime to time)Criteria to authorize the kit installer andresponsibility of vehicle / kit manufacturer/ supplier / installerInstallation certificate for converted CNG /BIO-CNG vehicleChecklist for third party checking orinspection of built-up CNG / BIO-CNGbuses (New and In-use) and LNG buses(New) before registrationChecklist for preventive maintenance ofin-use CNG / BIO-CNG / LNG vehicles10.Annexure IX34/9611.Annexure X12.Annexure XB13.Annexure XCChecklist for third party checking /inspection of CNG / BIO-CNG / LNGvehicles (other than CNG / BIOCNG/LNG buses) before registration (Newand In-use)Tests to be carried out by Test CNG / BIOCNG / LNG FitmentTests to be carried out by test agency(for retro fitment of in-use vehicle (CNG /Bio CNG/ dual fuel engine))Tests to be carried out by test agency(for replacement of in-use diesel engine bynew CNG / bio-CNG engine)14.AIS-028 (Version 5)Code of practice for use of CNG / BIOCNG/LNG fuel in internal combustionengined vehicles48/9615.16.Annexure XIAnnexure XIIAISC Panel CompositionAutomotive Industry StandardsCommittee 9645/9646/9647/96
AIS-024 (Version 5): 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 HCVvehicles only) operated vehicles using Dual Fuel technology in addition toDedicated and Bi-Fuel technology. It may be noted that Liquefied Natural Gas(LNG) shall be permitted for dedicated 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.IV
AIS-024 (Version 5): 2016SAFETY AND PROCEDURAL REQUIREMENTS FOR TYPE APPROVAL OF CNG/ BIO-CNG / LNG OPERATED VEHICLES (DEDICATED, BI-FUEL & DUAL FUELas applicable)For CNG / BIOCNG/LNG** Fitmentby OE Manufacturerfor New VehicleDocuments to be Specification of CNG /submittedBIO-CNG/LNG kit inthe given format as perAnnexure I.PerformanceTests as perCMVRFor Replacement ofIn-Use Diesel Engine byNew CNG / BIOCNGEngineSpecification of CNG /BIO-CNGkit as perAnnexure I.Specification of CNG /BIO-CNGkit as perAnnexure I.Technical specification ofthe retrofitted vehicle asper Annexure II.Technical specifications ofin-use diesel vehicle as perAnnexure II.Technical specification ofvehicle and CNG / BIOCNGengine as per Table 2and 4 of AIS-007.Certificates of originalpetrol/diesel enginedvehicles to be producedfor checkingcompliance of as manycommon rules ofCMVR for petrol/diesel vehicle and CNG/ BIO-CNG/LNGvehicle.Details of alterationscarried out on dieselengine to CNG / BIOCNG along with names ofthe supplier.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 theexamination andevaluation beforeundertaking performancetests on CNG / BIOCNGfuelled vehicles.Whichever rules are notcomplied with becauseof changes made forconversion, the sameare to be re-checked asper applicable CMVR.Assessment of structuralintegrity in case of heavypassenger/goods dieselvehicles to be provided bythe retrofitter or kitinstaller.Assessment of structuralintegrity in case of heavypassenger/goods dieselvehicles to be provided bythe retrofitter or kitinstaller.Detailed and brieftechnical specificationsof vehicle in AISCformat (AIS-007).CMVR ChecksFor Retrofitment ofIn-Use Vehicle (CNG /BIO CNG/ Dual FuelEngine)CMVR checks / testsare to be conducted byTest Agency as perCMVR No. 93 to 125.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 evaluationbefore undertakingperformance test on CNG /BIO-CNGfuelled vehicles.As per Annexure X-a As per Annexure X-b of As per Annexure X-c ofof AIS-024*.AIS-024*.AIS-024*.1/89
AIS-024 (Version 5): 2016Safety Checksas per AIS-028.As given in Annexure As given in Annexure IV As given in Annexure IVIV of AIS-024*.of AIS-024*.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/BIOCNGvehicleChecklistfor As per Annexure VII of thirdparty AIS-024*.checkingorinspectionofbuilt-up CNG /BIO-CNG/LNGbusesbeforeregistrationChecklistfor preventivemaintenance ofin-use CNG /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 .2/89
AIS-024 (Version 5): 2016ANNEXURE ITECHNICAL SPECIFICATION OF CNG / BIO-CNG/LNG KIT(DEDICATED, BI-FUEL & DUAL FUEL as applicable) *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)Max. test pressure (kg/cm2 ) /(MPa)Cylinder capacity (water equivalent)Approval reference from PESO4. Cylinder Valve(s) / Shutoff valve (PESOapproved/endorsed)a)b)c)d)h)e)Name of manufacturerModel name/Identification No.Type2Working pressure (kg/cm ) /(MPa)2Max. test pressure (kg/cm ) /(MPa)Approval reference from PESO5. CNG / BIO-CNG/LNG Solenoid Valve /Automatic shutoff valvea)b)c)d)i)Name of manufacturerModel Name/Identification No.TypeWorking pressure (kg/cm2 ) /(MPa)Max test pressure (kg/cm2 ) /(MPa)6. Petrol Solenoid Valvea) Name of manufacturerVehicle ModelYear of manufactureVehicle Registration/Identification No:Name of the Kit InstallerSignature with SealNameDesignationDateEngine No.Chassis No.Document No. (indicating also revisionstatus)Sheet No.--------of--------3/89
AIS-024 (Version 5): 2016b)c)d)e)Model Name/Identification No.Type2Working pressure (kg/cm ) /(MPa)Max test pressure (kg/cm2 ) /(MPa)7. Refilling valve / Refilling Receptaclea)b)c)j)k)Name of the manufacturerModel name/Identification No.TypeWorking pressure (kg/cm2 ) /(MPa)Max test pressure (kg/cm2 ) /(MPa)8. Pressure Regulatora)b)c)d)e)f)Name of manufacturerModel name/Identification No.Type2Inlet pressure (kg/cm ) /(MPa)Outlet pressure (kg/cm2 ) /(MPa)No. of stagesTo be added separately9. Vaporizer/Heat exchanger (for LNG)a) Name of manufacturerb) Model name/Identification No.c) Type10. CNG / BIO-CNG/LNG Filtera)b)c)d)e)Name of manufacturerModel name/Identification No.TypeInlet pressure (kg/cm2 ) /(MPa)Outlet pressure (kg/cm2 ) /(MPa)11. Oil Pump or Lubrication System, if anya) Name of manufacturerb) Type12. High Pressure Tubinga)b)c)d)e)f)g)Name of manufacturerModel name/Identification No.TypeWorking pressure (kg/cm2 ) /(MPa)Max. test pressure (kg/cm2 ) /(MPa)Outer diameter/Inner DiameterProtection quality (material used)13. Low Pressure Tubinga) Name of manufacturerb) Model name/Identification No.c) Typed) Working pressure (kg/cm2 ) /(MPa)e) Max test pressure (kg/cm2 ) /(MPa)f) Outer diameter/Inner Diameterg) Protection quality (material used)4/89
AIS-024 (Version 5): 201614. Gas-Air Mixera)b)c)d)Name of manufacturerModel name/Identification NoType & drawingVenturi Size15. Gas Injectora)b)c)d)Name of manufacturerModel name/Identification NoType & drawingInjector flow specs16. ON/OFF Switcha) Name of manufacturerb) Model name/Identification Noc) Type17. Ignition System & Wiring Harness (for CNG /BIO-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 layout18. Interfacing Unita) Name of manufacturerb) Model name/Identification No.c) Type19. Ignition Timing Advancera)b)c)d)Name of manufacturerTypeTiming on CNG / BIO-CNG/LNG modeTiming on baseline fuel.20. Fuel selector switcha) Name of manufacturerb) Model Noc) Type21. A) 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 components22. Brief Description of System IncludingDimensional Layout for Cylinder and other kitcomponents installation ventilation details etc.5/89
AIS-024 (Version 5): 201623. Catalytic Converter Make & Model24. Refilling valve interlocking switch (NA for LNG)a) Name of manufacturerb) Identification No.c) Type25. Current limiting Device (Fuse)a)b)c)d)Name of manufacturerIdentification No.Voltage/current ratingType26. Pressure Indicator / pressure sensora) Name of manufacturerb) Identification No.c) Type27. Service shut off valvea) Name of manufacturerb) Identification No.c) Type28. Compartment/Sub-compartment/Gas tighthousinga) Name of manufacturerb) Identification Noc) Type29. Conduita) Name of manufacturerb) Identification No.c) Inner & outer diameterd) Type30. Details of Seat/Upholstery/roof and side lininga) Name of manufacturerb) Model name/Identification No.c) Type31. Details of non-moisture retaining hardrubber/equivalent material padding/liningprovided for inner side of the cylinder mountingband(s)a) Name of manufacturerb) Identification No.c) Type6/89
AIS-024 (Version 5): 201632. Battery cut off switch(if applicable)(a) Name of manufacturer(b) Identification No.(c) Type33. 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 applicable7/89
AIS-024 (Version 5): 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) Typeb) Bore x Stroke, mmc) No. of Cylindersd) Displacemente) Compression Ratiof) Max Engine Outputg) Max Torqueh) Air Cleaneri) Oil Filterj) Fuel Filterk) Capacity of Cooling Systeml) Oil Sump Capacitym) Weight of Engine (Complete)n) Radiator Frontal Area (Core Area)4. Clutcha) Typeb) Outside Diameter5. Gear Boxa) Modelb) Typec) No. of Gearsd) Gear Ratio1st2nd3rd4th5th6the) Reversef) Front Axleg) Rear Axleh) Ratio6. Steeringa) Steering Wheel Diameterb) Ratio7. Framea) Long Member Size, mmb) Number of Cross Members8/89
AIS-024 (Version 5): 20168. 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. Weightsa)b)c)d)Maximum GVWMaximum Permissible FAWMaximum Permissible RAWKERB weight with 90% fuel (with sparewheel, tools, etc.)e) Maximum Gradeability in 1st Gear15. Seating Capacity9/89
AIS-024 (Version 5): 2016ANNEXURE IIICHECKLIST FOR FITNESS TESTS AND CERTIFICATION FOR IN-USEVEHICLES AFTER FITMENT / CONVERSION TO CNG / BIO-CNGMODE (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 applicable10/89
AIS-024 (Version 5): 2016Annexure IVSAFETY CHECKS FOR USE OF CNG / BIO-CNG/LNG FUELS ININTERNAL COMBUSTION ENGINED VEHICLES (AS PER AIS-028) &INDIAN GAS CYLINDER RULES(As amended from time to time)Sr.No.CNG / BIOCNG/LNG KitComponentCertifying /Verifying Authority1CNG/BIO-CNG/LNG Cylinder*PESO, Nagpur to certify or endorsein case of foreign make1.1Fitment ofcylinder onvehicleTest agency to verify as per AIS-028Clause no. 2.3, 2.5and 2.6 of AIS-0282CNG/BIO-CNG/LNG Cylindervalves/Shut offvalve *PESO, Nagpur to certify or endorsein case of foreign makeIS: 3224(for CNGvalves), ECE R110(for LNG valves)or Gas cylinderrules 2016 or asendorsed by PESORegulator (ForCNG & BIOCNG) /Regulator andVaporizer(LNG)*Testing of the component as perIS: 15713 or ISO-15500 by testagency. Alternatively, test agency toverify the test certificate or reportconforming to the above standardissued by accredited testinglaboratory.IS: 15713 or ISO15500LNG regulator andVaporizer/heat exchanger shallmeet requirements of ECE R110or equivalent standardECE R 110 orequivalentstandardTesting of the component as perIS :15714 or ISO-15500 by testagency. Alternatively, test agency toverify the test certificate or reportconforming to the above standardissued by accredited testinglaboratory.Testing of the component as perISO-15500-7 by test agency.Alternatively, test agency to verifythe test certificate or reportconforming to the above standardissued by accredited testinglaboratory.IS: 15714 or ISO 155004Gas-Air Mixer*5Gas Injector*11/89Clause of AIS-028/ Other Rules,Standards, etc.Gas cylinder rules2016 or asendorsed by PESOISO-15500-7
AIS-024 (Version 5): 20166Petrol SolenoidValve*Testing of the component as per IS:15717 by test agency. Alternatively,test agency to verify the testcertificate or report conforming tothe above standard issued byaccredited testing laboratory.Testing of the component as per IS:15712 or ISO-15500 by test agency.Alternatively, test agency to verifythe test certificate or reportconforming to the above standardissued by accredited testinglaboratory.IS: 157176.1Gas SolenoidValve / AutomaticShutoff valve*Automatic shutoff valve of LNGSystem (which comes in contactwith LNG shall meetrequirements of ECE R110 orequivalent standards)Automatic shutoffValve for LNGSystem : ECER110 orequivalentstandardsFilling Connection(NZS & NGV-1type)Installation on vehicle to be checkedby test agency as per AIS-028Clauses 2.2.2,2.2.3, 2.2.4, 2.2.5and 2.2.6 ofAIS-028LNG receptacleLNG receptacle shall meetrequirements of ECE R110 orequivalent standardECE R 110 orequivalentstandard8VentilationTest agency to verify.9Testing ofConduit*Testing of the component orverification of certificate or testreport as per IS: 15715 by testagency.71010.110.1.1CNG / BIOCNG/LNG fuellineHigh pressure —exceeding100 kPa*Exceeding 2.15MPa-Rigid pipeTesting of the component orverification of certificate or testreport as per IS: 15716 by testagency.LNG rigid pipeline shall meetrequirements of ECE R110 or IS:15716 or equivalent standard.12/89IS: 15712 or ISO15500Clause 2.4.2 ofAIS-028IS: 15715IS: 15716ECE R110 or IS:15716 orequivalentstandard.
AIS-024 (Version 5): 2016-Flexible hoseTesting of the component orverification of certificate or testreport as per IS 15718 by testagency.IS 15718 orAIS028LNG flexible pipeline shall meet ECE R110 or IS:requirements of ECE R110 or IS: 15718 or15718 or equivalent standard.equivalentstandard10.1.2Pressure upto2.15 MpaTesting of the component orverification of certificate or testreport as per IS: 15722 by testagency.LNG pipeline shall meetrequirements of ECE R110 or IS:15722 or equivalent standard.10.2Joints andconnections*11Compartment orSubcompartment*12Specific LNGcomponentsIS: 15722 withamendmentsECE R110 or IS:15722 or equivalentstandardTesting by test agency.Clause 3.1.4.1,3.2.1 (b) ofAIS-028LNG joints & connection shall meetrequirements of ECE R110 orequivalent standardTesting of the component orverification of certificate or testreport as per IS: 15720-2008 by testagency.ECE R110 orequivalent standardFollowing specific components, asapplicable shall meet requirements ofECE R 110 or equivalent standardECE R 110 orequivalentstandard LNG Fuel pump , Pressure ReliefIS: 15720-2008valves, Pressure sensor, checkvalve, excess flow valve, manualvalve and non-return valve.13Safety check forinstallation ofCNG / BIOCNG/LNG systemSafety checks to be carried out bytest agency as per AIS-028.Relevant clauses ofAIS-028* Certificate issued by accredited testing agency of the country of origin or a report issuedby internationally accredited test laboratory may also be accepted.NOTE 1-Only the standards, as amended from time to time, as mentioned above,shall be referred for compliance.NOTE 2-Components downstream the Heat exchanger/vaporizer shall beconsidered as CNG components and prevailing Indian standard /ISOstandard or equivalent standards shall be acceptable.NOTE 3-Test agency to conduct applicable CMVR test with LNG fuel asnotified by Govt of India13/89
AIS-024 (Version 5): 2016ANNEXURE VCRITERIA TO AUTHORIZE THE KIT INSTALLER ANDRESPONSIBILITY OF VEHICLE MANUFACTURER / KITMANUFACTURER / SUPPLIER / INSTALLER APPLICABLE TO CNG /BIO-CNG VEHCILES (DEDICATED/BI-FUEL/DUAL FUEL).The following are the criteria to be complied by the kit supplier/manufacturer forconversion of in-use vehicles to operate on CNG / BIO-CNG fuel.1. The replacement of engine / retrofitment of CNG / BIO-CNG kit shall be typeapproved by any one of the testing agencies specified in Rule 126 of the Central MotorVehicle Rules. The responsibility of the type approval and ensuring that the kitsmanufactured comply with the provisions and installation thereof shall be that of thevehicle/kit manufacturer/supplier as the case may be.2. Only the Installer authorized by vehicle/kit manufacturer/supplier shall fit the kit onvehicles. For this purpose, the vehicle/kit manufacturer/supplier shall issue acertificate of authorization to the Installer concerned duly authorizing them to fit thekit on behalf of manufacturer.3. Kit installer shall be equipped with the following tools and equipment. Two post lift / rampElectric hand drill machine and H.S.S. drill bitsTube benderTube cutterDeburring tool for tubeSet of ‘D’ ring and box spannersSet of screw driver (both flat and star)Set of allen keysH.S.S. hand sawCrimping tool for electrical cable terminationSoap bubble bottleSet letter and number punchInfrared pollution meterTiming gunFiller gaugeMeasurement tapeAir compressorFlame proof inspection lightVernier caliperMultimeterSilicon seal/sealantFirefighting equipment Dry chemical powder (DCP) typeMinimum two numbers of 5 kg each with ISI mark.CO2 type fire extinguisher – minimum 1 number of 5 kg with ISI mark.Fire buckets – 2 buckets.14/96
AIS-024 (Version 5): 20164. Installer shall have trained technicians having minimum ITI qualification and at leasttwo years of experience in the similar field. Vehicle/kit manufacturer/supplier toimpart extensive training to the technicians on CNG / BIO-CNGkit installation.5. Installer to display in the premises, authorization certificate issued by vehiclemanufacturer/kit manufacturer/supplier. Also, installer to display details of thefacilities available in terms of equipment and trained manpower.6. After obtaining the type approval certification, the vehicle/kit manufacturer/supplier(s)shall authorize the installer to undertake CNG / BIO-CNGconversion, who meets thefollowing requirements.i)Name and communication details like address, telephone number, etc. of theinstaller.ii) Business profileiii) Qualificationiv) Experiencev) Details of technical staff and equipmentvi) Specification of workshop/land use certificate from appropriate authority.The vehicle / kit manufacturer or supplier shall submit the above information to theregional transport authorities.7. Installer to carry out conversion/installation as per “Code of Practice for Use of CNG /BIO-CNGfuels in internal combustion engined vehicles (AIS-028)”.8. Installer to carry out the inspection, testing, commissioning & garaging/repair of CNG/ BIO-CNGsystem as per clause 7 & 8 of AIS-028”.9. Installer shall issue installation certificate as per Annexure VI of AIS-024, to thevehicle owner, that the conversion kit has been fitted in safe and proper manner, incompliance with “Code of Practice for Use of CNG / BIO-CNGfuel in Internalcombustion Engined Vehicles (AIS-028) ”.10. Installer to send a copy of installation certificate as per Annexure VI of AIS-024 andduly filled checklist as per “Appendix A of AIS-028 (for vehicles other than CNG /BIO-CNGbuses) / Annexure VII of AIS-024 (for CNG / BIO-CNGbuses)” to RTOand Test Agency, who has type approved the CNG / BIO-CNGconversion kit.11. The record of conversion / alteration of vehicles carried out by the kit installer shall bemaintained and made available to the authorities such as MORTH / Test Agencies /Transport Authorities as and when demanded.12. The vehicle owner shall apply to the concerned registering authority within 14 days ofundertaking the alteration, as required under Section 52 of Motor Vehicle Act 1988,for endorsement of particular alteration in registration certificate mentioning place anddate of installation and installation certificate number. This shall also be ensured bythe kit installer.13. The vehicle/kit manufacturer or supplier shall impart training to installer oninstallation, maintenance and operation of CNG / BIO-CNGsystem and issue thetraining certificate to installer after completion of training. The test agency may devisethe appropriate training programme as required.15/96
AIS-024 (Version 5): 2016The training shall encompass the following:13.1CNG / BIO-CNGTanka)b)c)d)e)13.2Fitments on tankLocation and ventilation of tanks.Construction of compartment and sub-compartmentInstallation of tankShieldingCNG / BIO-CNGFuel Linea) Testing of CNG / BIO-CNGfuel lineb) Flexibilityc) Installation13.3CNG / BIO-CNGControl Equipmenta) Installation of regulator and its functioningb) Installation of fuel selection switch and its information13.4Inspection, Testing and Commissioning of CNG / BIO-CNGSystema) Commissioningb) Leak testing13.5Garaging and Repaira) Repair operation of CNG / BIO-CNGvehiclesb) Scrapping13.6Periodic inspection13.7CNG / BIO-CNGCharacteristics and Safety Aspects for Handling and Storage14.The kit installer shall ensure compliance to the emission norms and Sub-rule 2 ofRule 115 and the code of practice for the use of CNG / BIO-CNGfuel in internalcombustion engined vehicles.15.Responsibility of the vehicle /kit manufacturer/supplier/installer:Theowner/driver shall be instructed in the correct way the gas system and controlsfunction along with a owners operation manual for the gas system outlining thefollowing:15.1Basic gas system explanation with a diagram15.2Fuel change over switch operation if bi-fuel /Dual fuel system is fitted15.3Starting procedure for cold and hot starting15.4How the vehicle is refueled15.5In the event of backfiring check procedure15.6In the event of a gas leak shut off procedure15.7Emergence or information contact numbers16/96
AIS-024 (Version 5): 2016ANNEXURE VIINSTALLATION CERTIFICATE FOR CONVERTED/OE CNG / BIO-CNG/LNGVEHICLE (DEDICATED/BI-FUEL/DUAL FUEL)(to be filled in by installer/OE)A. Details of Installer Approval:1. Installation Certificate issued byName and address of installer/OE2. Approval of installerName of vehicle manufacturer/kitmanufacturer/ kit supplier, who hasapproved the installer3. Type of vehicle converted (As perAIS- 053)4.Approval of the CNG / BIO-CNG/LNGkita)Name of the Test Agencyb)Approval Certificate No. & DateB. Details of Converted Vehicles1. Regn. No. & year of manufacture2. Chassis and engine No.3. Type of Operation (Bi-fuel / Dualfuel/ dedicated fuel)C. Details of CNG / BIO-CNG/LNG Kit1.Cylinders:a) No. of Cylinder/sb) Type of Cylinder/sc) Cylinder No/s.d) Makee) Water Capacity (litres)f) Working Pressure (kg/cm2 )g) Approval reference of PESOh) Validity of PESO Certificate2. Cylinder Valvesa) Makeb) Valve No.c) Working Pressure (kg/cm2 )d) Approval reference of PESO17/96
AIS-024 (Version 5): 20163. Refilling Valve :a) Makeb) Type4. Fuel Linea) High pressure pipe dia (ID/OD)b) Low pressure pipe dia (ID/OD)5. Shut Off Valve (Solenoid Valves)a) Makeb) Typec) Operation Voltage6. Fuel selection switcha) Makeb) Type7. Regulatora) Makeb) Typec) Sr. No.8. Gas-Air Mixer/ Injectora) Makeb) TypeNote:1) This certificate shall be filled and provided to vehicle owner for all vehiclesconverted for CNG / BIO-CNG/LNG operation.2) A copy of this certificate along with checklist as per Appendix A of safety documentshall be forwarded to RTO and test agency from where the approval for CNG / BIOCNG /LNG kit is obtained.3) It may be noted that Liquefied Natural Gas (LNG) shall be permitted for OEmanufactured Vehicles having GVW 3.5 T.Signature & Seal of OE/ Installer18/96
AIS-024 (Version 5): 2016ANNEXURE VIICHECKLIST FOR THIRD PARTY CHECKING / INSPECTION OFBUILT UP CNG / BIO-CNG BUSES (NEW AND CONVERTED / RETROFITTEDIN-USE)/LNG BUSES (NEW)BEFORE REGISTRATION FOR DEDICATED/DUAL FUELThis checklist is for third party inspection of fully built CNG / BIO-CNG / LNG busesbefore registration by RTOs. Reference to relevant clauses of Safety Code of Practice,e.g. AIS-028, and guidelines issued by Central Government from time to time should bemade wherever appropriate. It may be noted that Liquefied Natural Gas (LNG) shallbe permitted for OE manufactured Vehicles having GVW 3.5 T.A. Details of CNG / BIO-CNG/LNG Bus1. (a) Name and address of chassismanufacturer (applicable for new &Converted / Retrofitted in-use)(b) Name and address of retrofitter(applicable for Converted /Retrofitted in-use)(c) Name and address of enginemanufacturer(applicable forConverted / Retrofitted in-use)2. Name of type approval agency3. Details of type approval certificate4. Name and address of bus body builder5. Name and address of approvedinspecting agency at R.T.O.6. Chassis and engine No.7. Year of manufactureB. Detail of CNG / BIO-CNG/LNG System1. Checking of Cylinders as per PESO/vehicle testing agency approvals Validity of PESO Certificate19/96
AIS-024 (Version 5): 2016 Safety checksa. Check for corrosion on any CNG /BIO-CNG/LNG components /mountings of gas circuitb. Check whether cylinder is securelymounted within the vehicle andcheck tightness of nuts and boltsc. Check whether minimum 5 mmclearance is kept between cylindersand vehicle body structured. Distance between cylinder valveand bus body extremities shall notbe less 200 mm unless valves areprotected (as per the detailsprovided by the kit/vehiclemanufacturer/kit supplier and dulyvetted and approved by testagencies) to minimize thepossibility of damage due tocollision, overturning/ otheraccident.e. Check that the material of thepadding / lining provided for innerside of cylinder mounting band (s)is made up of EPDM non-moistureretaining rubber (hardness Shore A60 min.
7. Annexure VI Installation certificate for converted CNG / BIO-CNG vehicle 17/96 8. Annexure VII Checklist for third party checking or inspection of built-up CNG / BIO-CNG buses (New and In-use) and LNG buses (New) before registration 19/96 9. Annexure VIII Checklist for preventive maintenance of in-use CNG
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