Introduction
Auto LPG– An Environmental Friendly Fuel
Commercial Advantages
Product Knowledge
Special Characteristics of Auto LPG
A Brief Word Of Caution
Techno-Commercial Advantage Of LPG
Maintenance Chart
What Do You Always Wanted To Know About LPG FAQ's
Trouble-Shooting
Emergency Action
List of approved vehicles eligible for L.P.G. Retrofiting

INTRODUCTION

Liquefied Petroleum Gas (LPG) in one the most widely used alternative fuel all over the world for over 40 years. It powers more than 7 million vehicles in various countries due to its various environmental advantages.

Automotive LPG is a clean – burning, high octane number, environmental friendly transportation fuel with its proven success. High octane number ensures virtually no sacrifice in power. LPG under moderate pressure and reduced temperature can be stored in liquefied form.

AUTO LPG – AN ENVIRONMENTAL FRIENDLY F

UEL

• Clean efficient combustion.
• Among the lowest life-cycle greenhouse gas emissions of all commercially available fuels.
• Low sulphur content.
• High Octane number.
• Easy to transport.
• Faster refueling time as compared to other alternative fuels.
• Better anti – knocking properties than petrol. No modification on Engine.
• Very low emissions on carbon monoxide (CO), nitrogen oxide (NOx) and un-burned hydrocarbons.

COMMERCIAL ADVANTAGES

LPG fuel is much cheaper than petrol, saving can be between 45% to 50% on fuel costs as against petrol. This can vary with the petrol and LPG prices.

LPG has an anti knocking power which is comparable with Gasoline and superior to Diesel.

The oil drain period of car running on Auto LPG will increase and it will also extend the life of spark plug as Auto LPG is a clean fuel.

Adulteration or spilling or theft is not responsible.

LPG reaches the engine in pure form resulting in an improved air / fuel mixture and enables refined combustion.

There is hardly any discharge of CO (Carbon mono- oxide) as compared to petrol and diesel since the exhaust fumes contains less harmful substance.

The CO emissions are around 80% less than petrol and 40% less than diesel. Hydrocarbon emissions are 60% less than petrol and 50% less than diesel. Nitrous oxide emissions are around 80% less than petrol and 90% less than diesel. Carbon dioxide which contributes to global warming is less.

Existing fuel system is retained which can work as an option and thus increases the flexibility of the usage of the mode of fuel.

PRODUCT KNOWLEDGE

AUTO LPG CONVERSION KIT.

The Auto LPG conversion kits has been Type tested by Automotive Research Association of India, Pune for various parameters and also carried out safety checks as per international norms. The LPG Conversion kits are being imported from original Equipment Manufacturer M/s OMVL, Italy who have designed the kit s conforming to International Standards. The components and rubber parts used are designed for highest factor.

FUEL TANKS :-

The fuel tanks has been fabricated to IS standards IS: 14899 which has single opening on which multi function valve assembly is fitted.

Following gadgets and fittings are available on the tank to enhance safety:

(a)   Safety relief value
(b)   Fusible Plug.
(c)   Content Gauge
(d)   80% Fill Limiter
(e)   Non Return Valve
(f)   Remotely controlled valve with excess flow valve
(g)   A Gas tight housing / cover with a ventilation pipe.

The Cylinders have been designed to extreme temperatures of (-) 20 deg C to 65 deg C and to a design pressure of approximately 30 bars. The cylinders have been tested stringently at the factory like Hydrostatic stretch test, Burst test, Pneumatic leakage test, Bon Fire Test, Crash Fatigue test and also non destructive test like radiography of the weld joints etc.

By adopting all the above, it is found that lot of safety has been built in the equipment by way of design, manufacturing, testing and installation.

More over the LPG kits, and fuel tanks are fitted by trained mechanics at the RTO approved Retrofitting centers.

SPECIAL CHARACTERISTICS OF AUTO LPG

• Auto LPG is stored and delivered as a liquid under pressure.
• While changing from liquid to gas, LPG expands approximately 260 times its original volume.
• Leakage of liquid LPG is more sensitive than Gas LPG/CNG.
• LPG/CNG vapour is approximately 1.5 time heavier than air. So, LPG vapour tends to settle down.

A BRIEF WORD OF CAUTION

• Please do not buy or get installation done from unauthorized services.
• For installation, repairs, testing or any modifications approach only RTO approved retrofitment centres. List is given in the end of the booklet.
• Please fill your Auto LPG only through authorized Auto LPG dispensing stations and do not try to fill LPG by any other means.
• To get a good mileage use an engine which has compression ration of not less than 12 kg/cm2    
• Please report about mileage performance & other details to your retrofitment centre immediately after the 1st(or) 2nd fill. They will undertake adjustments and fine tuning.
• You may get cheaper services, unauthorized kits in the market, which are not legal. These kits in use may cause danger an even  fatal accident. Please do not use them.
• Avoid cellular phone usage at the filling stations.

TECHNO-COMMERCIAL ADVANTAGE OF LPG VIS A VIS CNG

Comparision Chart showing, approximately, how far various cars will travel for every Rs. 200.00 worth of Petrol and GAS.

Chevrolet Optra

MAINTENANCE CHART

Components / Operation	Daily	1000 KM	2000 KM	5000 KM	10000 KM	20000 KM	30000 KM
Leakages if any
Air Filter Cleaning
Air Filter Replacing
Compression Ratio
Spark Plugs Check
Spark Plugs Cables
Electrical Connections to Check
LPG Solenoid Valve Filter Cleaning
LPG Solenoid Valve Filter Replacing
LPG Hoses replacement
Vaporizer Diaphragms checking
Vaporizer Diaphragms replacing
Over all Kit checking
Servicing Kit
Water Pipes
Petrol Pipe replacing
Multivalve Kit Checking
Auto LPG Tank – Visual Inspection
Auto LPG Tank – Hydrostic Pressure Test						EVERY 5 YEARS

WHAT DO YOU ALWAYS WANTED TO KNOW ABOUT LPG/CNG

1.         ADVANTAGES OF LPG ON PETROL?

• LPG has an anti knocking power which is comparable with Gasoline and superior to Diesel.
• The oil drain period of car running on Auto LPG will increase and it will also extend the life of spark plug as Auto LPG is a clean fuel.
• Adulteration or spilling or theft is not responsible.
• LPG reaches the engine in pure form resulting in an improved air / fuel mixture and enables refined combustion.
• There is hardly any discharge of CO (Carbon mono- oxide) as compared to petrol and diesel since the exhaust fumes contains less harmful substance. The CO emissions are around 80% less than petrol and 40% less than diesel. Hydrocarbon emissions are 60% less than petrol and 50% less than diesel. Nitrous oxide emissions are around 80% less than petrol and 90% less than diesel. Carbon dioxide which contributes to global warming is les in LPG.
• Existing fuel system is retained which can work as an option and thus increases the flexibility of the usage of the mode of fuel.

2. IS IT LEGAL?

LPG as motor fuel is now legal, with the amendment of all statutory regulations, such as MV Act, MV Rules, LPG Control Order etc. vehicle owners have to use only approved brand of kits (Type approvals now being granted by the testing agencies) and get the vehicle R.C. book endorsed by the local R.T.O.

The retro-fitment of LPG kits can be carried out only by authorized workshops approved by RTO and Transport dept.

3. GAS & PETROL CAN WORK IN THE SAME ENGINE?

Yes, LPG like CNG can be used in bi-fuel mode for which selector switch is erected on dashboard, to activate Solenoid valve of either MS or LPG.

4. DUEL FUEL SYSTEM?

As stated above, you can start and run the car with either gas or petrol by using an electronic change over switch provided on dashboard.

5. SAFETY?

The LPG Conversion Kit have large number of inherent safety features and is also manufactured, tested and installed as per highest international standards. It is thus safe in all the ways to convert the vehicle using LPG Conversion kit.

To understand this better certain facts are to be given due consideration

Fixed Auto LPG Tanks are made as per BIS Standards to meet all safety requirements.

A tank can normally burst only in the event of a fire in a car where the surrounding temperature exceeds at least 400 – 500 degree centigrade which again never happens in a car due the presence of pressure relieving devices. The tank s fitted with Multi Function Valve which large number of safety fittings like Safety Relief Valve, Excess Flow Valve, ROV’s, fusible plug fitted on it.

6. WHERE IS THE TANK PLACED IN THE CAR?

IT is fixed in the luggage space of your car. It is fastened with metal strap so that it does not move while the car is running. As per BIS code it has to be permanently fitted tank and should be integral part of vehicle (As per BIS 14899 for fuel tank container and as per LPG Control order).

7. WILL AN EXCESS LOAD OF TANK EFFECT MY CAR SUSPENSION ?

No a car is designed to carry sufficient load. This is similar to carrying a passenger with luggage. Moreover, the weight of empty LPG tank of 60 Ltrs. capacities weighs not more than 20 kgs.

8. HOW WILL I KNOW THAT I SHOULD REFILL, THE GAS?

The content gauge on the multi valve and the indicator on the switch mounted on the dash board shows the level of LPG inside the tank.

9. HOW MUCH MILEAGE DO I GET FROM LPG?

1 Liter of LPG will give approx. 0.8 to 0.9 time mileage as petrol. For e.g. if a car on a petrol runs for 10 km the same will run for 8-9 km with 1 liter of LPG considering the lower cost of LPG 40% cost savings could be expected.

10. WILL IT AFFECT MY CATALYTIC CONVERTER?

No, it will not damage any part of the engine or fuel system. There is no lead in LPG.

11. HOW IS ITS PERFORMANCE?

Very low emissions, no smoke, no compromise on the pick up.

12. IN THE EVENT OF ANY LEAKAGE WILL IT EXPLODE?

As explained earlier the fuel tanks have several pressure relieving devices to avert any blast or explosions. This is demonstrated in Bonfire tests, where in the car is set on fire. The leaked product from the vent will jet out from the rear tyre, but even after prolonged fire there are no explosions occurring due to the provision of pressure relieving devices.

13. IN A SMALL CAR LIKE MARUTI WILL IT NOT OCCUPY MY LUGGAGE SPACE?

A smaller tank is fitted in small cars to facilitate easy removal of Stepney Torroidal tanks (in the shape of a tyre) can also be installed which help to save luggage room. Alternatively small tanks 36 Liters are available to conserve the space.

14. WILL THERE BE ANY SMELL IN THE PASSENGER CABIN?

Ethyl Mercaptan is added in 20 PPM to Auto LPG to detect the leakage. This is a safety feature. At the time of installation a proper leakage test is done and a leakage free installation is ensured.

15. WHAT IS THE PRICE OF THE CONVERSION KIT?

For Carburetor Cars Rs. 23000/- including installation/fitting charges.

16. WHAT IS THE PRICE OF THE CONVERSION KIT OF SEQNENTIAL GAS SYSTEM.

For Carburetor Cars Rs.55000/- including installation/fitting charges.

17. PROCEDURES FOR APPROVAL WITH R.T.O.?

On getting your vehicle converted with an approved LPG conversion kit, the Retro-fitment Centre will facilitate the endorsement in the vehicle R.C. Book by the local R.T.O. this endorsement allows legal use of the kit in your vehicle.

18. CAN WE USE CNG KITS AND TANKS ON LPG FUEL?

– NO

The properties and characteristics of CNG and LPG are different. The safety relief valves and other devices are set for a particular pressure of LPG. There is no fill limiter in case of CNG tanks as it meant for the Services of Gas. The fill connections are also different for LPG and CNG. Hence, not advisable to use CNG kits for LPG Service.

IS AUTO LPG SAFE?

YES, LPG is absolutely safe and in fact safer than petrol

The gas is stored in the vehicle in liquid form and contained in an Auto LPG Tank. The Tank is designed from special low carbon steel.

Tests and practical experiences have shown that LPG can only ignite or cause a fire if it leaks and spreads air tight area and then it is ignited, such a situation does not arise in automobile as the as the engine compartment is open to air and any leaked gas will escape.

Moreover these are the same kits as used in European countries if the Autogas system and tanks were not safe would the large number of car users in America, Australia and Europe where there are stringent safety norms have changed their vehicles to run on Autogas?

Whit all this you have to ensure that you use a good quality approved kit as these kits undergo rigorous tests ensure safety, also ensure that you have the kit fitted by an approved Retrofitment Center

DUAL MODE OPERATION

The 3 way/2 way switch provided on dash board will allow the car to run on LPG or Petrol mode.

RETROFITTING THE KIT

The auto LPG Kit can only be fitted by the authorized Retrofitment Centre which is approved by the Transport Commissioner’s Office (RTO’s). Any petrol driven vehicle can be converted to LPG mode with prior approval of test agencies and RTO’s

ENGINE LIFE

Use of LPG can reduce engine maintenance and wear and tear in engines. Like :
(a) Can increase the life of spark plugs.
(b) Less frequent change of engine oil.
(c) Due to this engine life can be increased.

OPERATING PRECAUTIONS TO BE FOLLOWED BY VEHICLE OWNERS

The fuel selector switch has 3 positions: LPG, Neutral, and Petrol. To switch over to LPG mode (in carburetor vehicles), change the switch position to centre (neutral/no fuel position). Immediately switch over to gas mode as soon as the vehicle begins to stall. The same procedure should be followed for switchover from LPG mode to petrol mode.

After installation of the LPG kit, visit your Authorized kit installer in two weeks time and give him your feedback of the performance of your vehicle on LPG.

Like in case of petrol driven vehicles, get the vehicle checked at your Authorized Kit Installer for tune – up. This should be done every 5000 kms.

Replace sparkplugs and air filter every 12,000 kms to give optimum performance on LPG.

In the event of a smell of LPG leakage, run the vehicle in petrol mode and visit your Authorized Kit Installer for a check up.

Your vehicle should give you 40% and more savings on running cost as compared to petrol (present day prices are considered), if the kit is installed correctly and tuned properly and the engine should give 80% of mileage as compared to petrol.

Do not get your LPG Conversion Kit serviced at any un – authorized centre.

Every morning start and run the car on petrol and after warm un of engine, switch over to LPG. It is advisable to run the vehicle in petrol mode once in a while to prevent damage to petrol electronic fuel pump. Before parking the vehicle to rest at the end of the day, for a few minutes in petrol mode.

Never allow unknown garage person to service.

Servicing and repairs should only be done by and authorized retrofitment centre.

TROUBLE SHOOTING

A) If the car does not run on gas or petrol

Start the vehicle on petrol mode and run for 2 kms on petrol then switch to LPG mode (To be done only for the first start in the morning. This is to keep the petrol system intact and proper functioning on petrol mode)

B) Check the solenoid valve – operation – On and Off –

To be checked by retrofitment center. If the solenoid valves don’t operate, check the switch earth wire whether the connection is – proper – by Retrofitment centre.

C) The car does not have good acceleration

Check the cooper tubes and LPG Hoses to be checked by Retrofitment centres

D) Keep the air filters clean or change the air filter every 5,000 to 8,000 kms.

E) Check the spark plugs every servicing on petrol / gas system

EMERENCY ACTION

a) In case of leakage stop using LPG and switch over to petrol mode. Ensure the leakages have been stopped and then contact nearest retrofitment centre. (list of authorized retrofitment centre is enclosed at the end of the booklet)

b) In case of fire, take the vehicle to a safe open place and arrange for barricading the vehicle. Inform fire brigade (101) and police (100).

LIST OF APPROVED VEHICLES ELIGBIBLE FOR L.P.G. RETROFITING TILL DATE

LIST OF APPROVED CARBURETOR VEHICLES.