ICE To CNG
Vehicle converted to CNG:
- No Power Losses and follows the torque curve of Diesel Euro IV/VI compatible based on bus engine selected Simple and Compact.
- Optimum fuel economy due to better fuel control.
- Repeatability and Reliability of performance.
- No compromise in Drivability and Pick-up.
- Easy diagnosis. Self-Diagnosis system.
- Easy to install and calibrate.
- Based on vehicle selected long range can be achieved.
- In the unlikely event of failure to demonstrate performance bus can be reconverted to diesel.
- Provide warranty period service and support assurance based on routes where buses would operate apart from training local staff for any minor work.
- Can take service contract and support with spares and service based on the routes bus would operate.
- Based on the number of buses converted by us, an engineer can be stationed at one of the depots.
Range & Comparison
Total WC | Gas Kgs | Range Kms* | Steel Cyl | Composite Cyl |
---|---|---|---|---|
Weight Kgs | Weight Kgs | |||
1500 | 225 | 900 | 1600 | 396 |
1360 | 204 | 816 | 1400 | 380 |
1125 | 169 | 676 | 1200 | 297 |
1020 | 153 | 612 | 1100 | 285 |
750 | 113 | 452 | 800 | 198 |
680 | 102 | 408 | 720 | 190 |
- Assuming that fuel efficiency is 4 Kms/kg of CNG.
- Frames, piping, valves, supports, cabinet are designed for minimum weight.
- Lower weight means better fuel efficiency, better safety, lower cost of design.
Focus Areas
- Filling to Firing complete solutions available for a OEM.
- Partnership to offer integrated solutions with engine management systems
- Connected diagnostics, Driver feedback, Vehicle range monitor, Ecofuel mode features.
- Integrated R&D to develop new cylinder solutions
- Design and development of components and systems to increase safety and efficiency across the fuel systems with lower cost
- OEM & In-field conversion of systems on case to case basis for common platforms
Double Decker CNG System
- Scania Chassis & Alexander Dennis Body.
- First Biogas-powered double decker bus in the world.
- UK will have 190 buses by 2018.
- Two cylinders only: all carbon 2 x 515L.
- 1,030L @250bar with very limited space envelope.
- Lightest & simplest concept in the world – 577 kg.
Simplified Plumbing
- Utilization of large-capacity type 4 cylinders enables a significant reduction in the number of pipes and connectors.
- Reduces the cost and complexity of the CNG fuel system.
- Reduces the number of leak points.
- Simplifies and reduces the cost of maintenance Neck mounted cylinders have many advantages compared to strap mounted cylinders.
- Maintenance free.
- Rotation ability during visual inspection.
- Sliding end of the cylinders’ neck mount allows for cylinder expansion without creating stresses to the plumbing, frame, and other components.
Lightweight and Safe Rooftop CNG Systems
Longitudinal
Transverse
In-Body
Frame Rail
ProCab & ProRail CNG Systems
- Patented Designs
- Plug & Play Designs
- Crash tested for safety
- Integrated filling & storage
LNG Points to Note
- Natural Gas when liquified is LNG and when compressed is CNG.
- When space on vehicle is low, range required is long then LNG can be a good option.
- If however space is not a constraint, based on duty cycle LNG or CNG can be decided.
- Vehicle efficiency does not change in either case For a similar.
- The only issue with LNG is that if the vehicle is not on regular/ continuous duty cycle the gas will boil off/vent and fuel is lost.
- Professionally choice of fuel on any automobile must be based on vehicle design/ structure, range required and duty cycle & this can be a combination of LNG or CNG in a fleet.
- Engine conversion is FULL conversion & not half conversion like others.
- Stainless steel and high quality Swagelok/Parker/SSP components used.
- Designs, components, assembly – all as per OEM recommended standards.
- Futuristic features included in engine management unit that aids fleet operators in better efficiency, management and control.
- Dual fast/slow fill options to ensure that customer can get maximum fuel loading.
- Professional after-market support including AMC for vehicles.
- Follow statutory and other requisite guidelines to ensure that customer has no surprises in future.
- Piping routing designs as per ARAI recommended design and safety guidelines.
Broad list of works
Sl No. | Work Item |
---|---|
1 | Modification and Calibration of Engine |
2 | Installation of Engine on Vehicle |
3 | Installation of CNG components, piping, cylinders, brackets on Vehicle/ Bracket |
Design | |
4 | Installation of Wiring harness on vehicle and integration of different vehicle functions |
like Dash Gauges, AC etc. | |
5 | Calibration of Gauges and other dash lamps |
6 | Calibration of Vehicle on Road |
7 | Release of Field Documents Service Manual, Troubleshooting Manual, Parts Catalogue, Training Manual and Safety Bulletin |
8 | Service Personal Training |
9 | Start of regular/ bulk retro fitment as per defined process |
Type 4 Cylinders
- Over 50 years of manufacturing experience.
- 25+ year operating service history with Type 4 cylinders.
- Type 4 in operation globally since 1993.
Benefits of T4 Composite Cylinders
- Latest technology in the world.
- Technology history since 1963 & commercial history since 1993.
- Lightweight – 70% LOWER in weight than Steel.
- For comparable weight & capacity system cost is competitive.
- Zero rusting or corrosion.
- Zero damage against Chemicals/ UV/Impurities found in natural gas.
- International practices do NOT specify periodic hydraulic retesting – only visual inspection needed.
- Infinite fatigue life.
- Demonstrated safety in mission critical applications like Space Shuttle.
- Behaviour of T4 Cylinder in a fire very different than Steel – much higher safety.
- High impact strength.
- Burst pressure of 550 bar & above for operating pressure of 200 bar.
- The low weight combined with efficient system design gives options of long range travel for both bus and truck applications.
- No risk of metal embrittlement when used with Hydrogen.
- Lifetime cost lower than steel, system cost comparable to steel.
Commercials – Lower Cost
The benefits of this solution is in the system design in terms of:
- Lower weight.
- Lower cost of assembly.
- Lower cost due to minimum piping.
- Lower risk of leak points.
- Lower maintenance cost.
- Lower recertification cost.
- Lower risk on safety due to visual inspection as per international standards.
- Lower cost of bus structure itself owing to low system weight.
- Lower cost to provide brakes, suspension etc. to cater to higher weight.
- Designing vehicles for new applications & markets.
- Meeting the planned emission norms of Euro/Bharat 6 today.
- Local design/ assembly
- Land for cylinder manufacturing procured
- System solutions from design to assembly for complete fuel system
- filling to firing
- Integration with vehicles can be done in suitable premises Post sales service and support network
- System and support for periodic recertification will be provided in consultation with statutory authorities
- OEM/ Fleet owner service teams will be trained to handle systems with back up service engineers/ infra