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
  1. Assuming that fuel efficiency is 4 Kms/kg of CNG.
  2. Frames, piping, valves, supports, cabinet are designed for minimum weight.
  3. 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
cng Benefits