Propane 101. Study Guide. Course Code: 8517

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1 Propane 101 Study Guide Course Code: 8517

2 2015 Navistar, Inc Navistar Drive, Lisle, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc.

3 1 Propane 101 Study Guide Table of Contents Introduction... 1 Objectives... 1 Properties of Propane... 2 Vehicle Refueling... 5 National Safety Codes... 7 Operating a Propane Fueled Vehicle... 8 Fuel Tank... 8 Vehicle Markings... 8 Fuel Tank Mounting... 9 Driving... 9 In Case of Emergency Conclusion NOTES THE INFORMATION PROVIDED WITHIN THIS COURSE IS FOR TRAINING PURPOSES ONLY. ALWAYS CONSULT THE LATEST SERVICE, DIAGNOSTIC, AND TOOL INFORMATION, LOCATED ON NAVISTAR S SERVICE PORTAL, PRIOR TO PERFORMING SERVICE ON NAVISTAR ENGINES, VEHICLES, AND EQUIPMENT. Introduction Welcome to the Navistar training course: Propane 101. This course is intended to introduce learners to propane as a fuel source for over the road vehicles. Objectives Propane is a safe alternative fuel that is used to lower emissions while also reducing particulate matter and lowering noise pollution. Upon completion of this course, the student will be able to: Describe the properties of propane Describe how to properly fill a propane autogas fuel system Identify possible Authority Having Jurisdictions Describe how to safely and efficiently operate a propane-autogas-fueled vehicle.

Propane 101 Study Guide 2 Properties of Propane Propane is a hydrocarbon also known as Liquefied Petroleum Gas, LP-Gas, LPG or when powering a vehicle, Propane Autogas.

Many people use propane in and around their homes for furnaces, water heaters, generators, outdoor grills, fireplaces, and appliances.

Propane autogas is a top choice as an alternative fuel. The PSI 8.8L engine in the IC CE Bus provides smooth acceleration and diesel like torque.

4 Propane 101 Study Guide 2 Properties of Propane Propane is a hydrocarbon also known as Liquefied Petroleum Gas, LP-Gas, LPG or when powering a vehicle, Propane Autogas. When handled properly, propane is a safe, clean burning fuel that is not harmful to the environment. Even when unburned, propane is non-toxic and presents no hazards to soil or groundwater. Many people use propane in and around their homes for furnaces, water heaters, generators, outdoor grills, fireplaces, and appliances. Over 95% of the propane used in the United States is produced in North America, and in the United States, propane autogas is the third most common fuel, after gasoline and diesel. Propane autogas is a top choice as an alternative fuel. The PSI 8.8L engine in the IC CE Bus provides smooth acceleration and diesel like torque. With the most developed refueling infrastructure of any alternative fuel in the United States, making the switch to propane is easier than ever. When used to fuel motor vehicles, propane autogas is stored in purpose-built puncture resistant tanks. These autogas tanks are sturdier and less prone to puncture than gasoline tanks. Propane also has a narrow range of flammability compared to other petroleum products. If the propane and air mixture contains less than 2.2% propane, it is too lean to burn. Similarly, if the mixture contains more than 9.6% propane, it is too rich to burn.

THE AHJ IS THE ORGANIZATION, OFFICE, OR INDIVIDUAL RESPONSIBLE FOR ENFORCING THE REQUIREMENTS OF THE CODE. Propane is produced as a result of processing natural gas or crude oil.

5 3 Propane 101 Study Guide TO PREVENT PERSONAL INJURY AND / OR DEATH, AVOID INHALING A HIGH CONCENTRATION OF PROPANE VAPORS. PROPANE IS HEAVIER THAN AIR AND WILL COLLECT IN LOW LYING AREAS WHICH CAN DISPLACE OXYGEN IN THE LUNGS. ALWAYS CONTACT THE LOCAL AUTHORITY HAVING JURISDICTION (AHJ) FOR VENTILATION REQUIREMENTS. THE AHJ IS THE ORGANIZATION, OFFICE, OR INDIVIDUAL RESPONSIBLE FOR ENFORCING THE REQUIREMENTS OF THE CODE. Propane is produced as a result of processing natural gas or crude oil. TO PREVENT PERSONAL INJURY AND / OR DEATH, AVOID SKIN CONTACT WITH PROPANE. LIQUID PROPANE BOILS AT -44 F (-42 C) WHICH MAY RESULT IN FROSTBITE. In nature, propane exists as a gas. However, when cooled to -44 F (-42 C), propane condenses into a liquid. Propane also becomes a liquid when it is pressurized for storage.

6 Propane 101 Study Guide 4 TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY AND / OR DEATH, BEWARE OF LIQUID PROPANE LEAKS. BECAUSE OF THE LARGE EXPANSION RATE, A LIQUID PROPANE LEAK CAN BE MORE HAZARDOUS THAN A PROPANE VAPOR LEAK. Propane expands at a very high rate when it evaporates. During this time, one volume of liquid propane will instantly expand to become 270 volumes of propane vapor.

5 Propane 101 Study Guide TO PREVENT PERSONAL INJURY AND / OR DEATH, ALWAYS RESPOND IN ACCORDANCE WITH LOCAL AHJ GUIDELINES TO EVEN A FAINT ODOR OF PROPANE.

7 5 Propane 101 Study Guide TO PREVENT PERSONAL INJURY AND / OR DEATH, ALWAYS RESPOND IN ACCORDANCE WITH LOCAL AHJ GUIDELINES TO EVEN A FAINT ODOR OF PROPANE. Propane is naturally colorless, odorless, and tasteless. However, a strong unpleasant-smelling chemical is added to it to aid in detection. This results in propane smelling similar to rotten eggs or a skunk's spray. Always respond in accordance with local AHJ guidelines to even a faint odor of propane. Vehicle Refueling TO PREVENT PERSONAL INJURY AND / OR DEATH, ALWAYS WEAR APPROPRIATE GLOVES AND SAFETY GLASSES AS WELL AS ANY PERSONAL PROTECTION EQUIPMENT (PPE) REQUIRED BY THE LOCAL AHJ SINCE LIQUID PROPANE BOILS AT -44 F (-42 C). To begin refueling a propane-autogas-fueled vehicle, turn off the vehicle. Be sure to wear appropriate Personal Protection Equipment (PPE), and avoid all sources of ignition, including the ones shown here. Always read and follow the fueling site's guidelines before dispensing propane autogas. Once properly equipped, open the fuel door and unscrew the dust cap from the vehicle fill valve.

Propane 101 Study Guide 6 TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY, AND / OR DEATH, ALWAYS ENSURE THE NOZZLE IS PROPERLY THREADED ONTO THE FILL VALVE AND THE SEAL IS IN GOOD CONDITION BEFORE

Since propane boils at such a low temperature, it must be dispensed in a closed system to ensure it remains in liquid form.

8 Propane 101 Study Guide 6 TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY, AND / OR DEATH, ALWAYS ENSURE THE NOZZLE IS PROPERLY THREADED ONTO THE FILL VALVE AND THE SEAL IS IN GOOD CONDITION BEFORE DISPENSING FUEL. AN IMPROPERLY THREADED NOZZLE OR DAMAGED SEAL ON THE FILL VALVE MAY LEAD TO A DANGEROUS LEAK. Since propane boils at such a low temperature, it must be dispensed in a closed system to ensure it remains in liquid form. While refueling, the system's seal is maintained by a threaded connection and a gasket. Do not attempt to fill the tank if the seal is damaged or missing. After verifying that the seal is in good condition, remove the nozzle from the dispenser. Connect the nozzle to the vehicle and tightly secure the threaded connection, and then squeeze the trigger to allow propane autogas to flow into the tank. PROPANE TANKS ARE CONSIDERED FULL WHEN THEY ARE FILLED TO 80% OF THEIR CAPACITY. THIS ALLOWS THE PROPANE TO SAFELY EXPAND WHEN EXTERNAL TEMPERATURES RISE. Propane tanks should not be filled to more than 80% of their capacity. The left over space allows the propane to expand safely when external temperatures increase. When the dispenser handle is released and / or the nozzle is unscrewed, it is normal for a small amount of propane vapor to be released into the atmosphere. If more than a small release of propane occurs, follow the fueling station's instructions to resolve the issue. After unscrewing the nozzle, return it to the dispenser, reinstall the dust cap on the vehicle fill valve, and shut the fuel door. If applicable, record refueling information at this time.

9 7 Propane 101 Study Guide National Safety Codes Safety should be the number one concern in every repair facility. This is especially true when introducing a new fuel source, such as propane. The first step is to ensure the building and work areas follow the proper codes. ALL NATIONAL CODES ARE ADOPTED VOLUNTARILY BY EACH STATE. ALWAYS CONTACT THE LOCAL AUTHORITY HAVING JURISDICTION (AHJ) FOR CODES REGARDING THE BUILDING OR MODIFYING OF A PROPANE-AUTOGAS-FUELED VEHICLE REPAIR FACILITY. IN SOME CASES, THE AHJ MAY HAVE OTHER REQUIREMENTS IN ADDITION TO THOSE CITED IN NATIONAL CODES. Several national codes such as the National Fire Protection Association (NFPA) Code for Motor Fuel Dispensing Facilities and Repair Garages, International Building Code (IBC), and National Electric Code (NEC) help outline the detailed requirements for building or modifying a vehicle repair or maintenance facility. These codes, for the most part, give the requirements for traditional liquid fuel facilities that service gasoline and diesel-fueled vehicles but do not directly address alternative fuels such as propane autogas. Always contact the local AHJ for codes specific to your location. The local Authority Having Jurisdiction could be the state fire marshal, fire chief, building inspector, or other official. As always, a Safety Data Sheet (SDS) must be made available to all workplace employees when storing or handling propane. The SDS contains information on physical properties, first aid, and other important aspects of propane. Always contact your local AHJ for propane service requirements that apply to your location, such as the ones shown here.

10 Propane 101 Study Guide 8 Operating a Propane Fueled Vehicle TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY, AND / OR DEATH, PROPANE TANKS SHOULD NOT BE CRACKED OR DAMAGED. NEVER OPERATE A VEHICLE THAT YOU SUSPECT MAY BE UNSAFE. ALWAYS CONTACT THE LOCAL AHJ FOR RECOMMENDED RESPONSE TO A SUSPECT TANK. Before operating a propane autogas fueled vehicle, there are a few things to note. These include facts about the fuel tank, vehicle markings, fuel tank mounting, and how the vehicle performs when driving. Fuel Tank The propane autogas is stored in purpose built tanks that have been rigorously tested and are designed for road travel, pressure, and inclement weather. Propane autogas tanks are also equipped with pressure relief valves; overfill protection devices; and automatic closures for added safety. The pressure relief valves and overfill protection devices prevent the internal tank pressure from climbing too high by leaving room for expansion and even safely venting some propane if necessary. The automatic closures can be used to seal the tank when the vehicle is turned off or if a connection is damaged. Vehicle Markings All propane autogas fueled vehicles are required to have certain markings on the exterior of the vehicle. The first marking is the propane autogas label which is typically attached to the right rear of the vehicle. The standard label is a black diamond-shaped decal with the word "PROPANE" in reflective letters. Some vehicles may use a blue diamond-shaped decal instead. Another important marking to identify is the one for the fuel shut-off valve. This marking displays the location of the shut-off valve, which allows the fuel source to be turned off quickly if needed.

9 Propane 101 Study Guide Fuel Tank Mounting Before entering the vehicle, note the location of the tank. Depending on the type of vehicle, the fuel tank may be inside or outside of the vehicle.

11 9 Propane 101 Study Guide Fuel Tank Mounting Before entering the vehicle, note the location of the tank. Depending on the type of vehicle, the fuel tank may be inside or outside of the vehicle. Externally mounted systems are often protected by cages and shielding to protect the fuel system. Driving Once the vehicle is on the road, driving a propane-autogas-fueled vehicle is very similar to driving a vehicle powered by gasoline. The high evaporation rate of propane means more of it will be ready to burn when injected into an engine, resulting in a more efficient burn. Since propane autogas is burned more efficiently in an engine, it provides the smooth acceleration of a gasoline engine, along with the torque of a diesel engine. An efficient burn also means there will be less particulate matter in the exhaust.

12 Propane 101 Study Guide 10 In Case of Emergency TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY, AND / OR DEATH, IF YOU SMELL PROPANE AT ANY TIME WHILE YOU ARE DRIVING, TURN OFF THE IGNITION, GET OUT OF THE VEHICLE, AND CALL 911 ONCE YOU ARE A SAFE DISTANCE AWAY. ALWAYS CONSULT THE OWNER'S MANUAL AND COMPANY POLICIES PRIOR TO OPERATING A PROPANE-AUTOGAS-FUELED VEHICLE TO DETERMINE WHAT STEPS TO TAKE IN THE EVENT OF AN EMERGENCY. TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY, AND / OR DEATH, DO NOT ATTEMPT TO CLOSE THE MANUAL SHUTOFF VALVE IF THERE IS IMMEDIATE DANGER. While propane is safe to use, it is extremely important to know what to do in case of an emergency. Some steps the owner's manual may include are: Turning off the ignition switch to remove a source of ignition. Opening all doors to the vehicle to allow venting if it is safe to do so. Turning off the manual shut-off valve if it is safe to do so. Immediately leaving the area and call or your local fire department. Not returning to the area or restarting the vehicle until an emergency responder says it is okay, and a qualified professional has inspected the vehicle for and ensured there are no leaks or damage.

13 11 Propane 101 Study Guide Conclusion This concludes the Propane 101 Navistar training course. Thank you for your participation. NOTES

2015 PSI 8.8L LPG Engine Overview. Study Guide. Course Code: 8777

2015 PSI 8.8L LPG Engine Overview Study Guide Course Code: 8777 1 2015 PSI 8.8L LPG Engine Overview Study Guide 2015 Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532. All rights reserved. No part of