Astra H
|
Safety regulations for gas-powered vehicles (natural gas / LPG liquid gas) 7.1 General The following danger notes and safety regulations exclusively apply to maintenance and repair work on Opel vehicles. Natural gas / liquid gas is a hazardous substance and must be treated, stored and identified accordingly.
Natural gas-driven vehicles (CNG = Compressed Natural Gas) are recognisable from the following features:
Vehicles with liquid gas drive (LPG = Liquefied Petroleum Gas) can be identified from the following features:
Operating with explosive and flammable substances is subject to varying national legislation which must be observed at all times. It is essential that established technological regulations and the legislation of the respective country are observed. Observe the relevant national regulations when handling and disposing of hazardous substances (e.g. residual gas in the pressurised gas tanks). At all workplaces in which hazardous substances are handled, the general national handling regulations of the hazardous substances legislation must be observed. Observe the relevant environmental, health and work safety regulations regarding explosive and flammable substances. In addition, the national legal requirements for other sectors such as accident prevention, hazardous substances legislation, hazardous goods, traffic and building regulations etc. must be observed. Specific national legislation and guidelines for the respective country must be observed to ensure work safety. For the prevention of fire and explosive hazards in conjunction with drilling, cutting, grinding or welding operations and material processing, the appropriate guidelines and regulations with regard to accident prevention issued by the specific national authorities must be observed. When working on the gas system or the gas storage equipment, fire, naked flames, smoking and ignition sources are prohibited and sparks must not be generated. People's attention should be drawn to this by placing hazard-warning signs in the gas system repair area. The prohibition of smoking must be clearly and permanently indicated by the presence of the relevant hazard-warning sign in the workshop and at access points. When the gas system is being re-started it must be checked whether the gas system and the pressurised gas tank are still accepted by the responsible authority (see gas container) and the maximum permitted operating period has not been exceeded. If the testing deadline or the maximum operating period has been exceeded, the vehicle can continue to be used with the remaining system pressure, but must not be refuelled. If possible, it should be ensured that pressurised gas tanks (natural gas) with the same expiry period are installed. If a pressurised gas tank is found to be faulty or damaged so as to constitute a hazard for operators or third parties, it must be safely discharged without delay. If this is not possible, alternative, suitable measures for hazard prevention must be taken. When the gas system is filled, the information in the relevant operating instructions for the vehicle and the refuelling system must be complied with. It must be checked whether the testing deadlines or the maximum operating period for the pressurised gas tank have been reached or have expired. Avoid damage to gas system components such as the pressurised gas tank. In order to protect the filler valve from damage, water and soiling, it must be closed again immediately after refuelling, emptying the gas system or carrying out leak testing. A completely or partially assembled system must not be left unsealed. The operation of CNG vehicles without gas storage systems is prohibited and results in the cancellation of type approval. In the event of injury or feeling unwell due to contact with hazardous substances, medical attention must be sought immediately. If possible, the doctor must be informed of the type of hazardous substance involved.
7.2 Repair Information In the workshop, two separate working areas are required, in which specific demands are made upon work safety and equipment, due to the differing hazards which prevail:
Therefore, before commencing an operation, the type and scope of the repair work must be checked. Before commencing an operation, it must also be checked whether the suggested repair work is in accordance with the current technological standards for maintenance work on the gas system. Gas-powered vehicles such as vehicles with gasoline engines can be dealt with during normal maintenance and repair work (with the exception of work on the gas system). This does not apply to vehicles with a leaking gas system. Non-gas-related maintenance and repairs can also be performed by mechanics who have not had gas training if they have been instructed by a skilled worker (member of staff with gas training) and the work has been accepted (inspected). However, the staff must be aware of the relevant regulations and rules (BGR157, GUV17.1 etc.) and have been given instruction on special gas-specific features. The following generally applies: maintenance and inspection work on the gas system may only be carried out by trained and qualified staff who have been given Opel gas service training in workshops set up for this purpose. Repair work on gas system components such as pressure reducers that are not described in the service instructions is not permitted. These components must never be forced open or modified. No holes may be drilled in the underbody area, from the interior of gas-driven vehicles. This is indicated by the stickers "Caution, tank system: drilling / grinding prohibited" in the vehicle interior and on the cover for the pressurised gas tanks. If there are no stickers in the appropriate places, these must be applied. The pipe connections are manufactured to very fine tolerances. In order to check the screw connections for correct fitting, a leak test must be performed. Because a variety of different bolts and screws are used, make sure that you are using the correct ones. Do not mix them up. Before all work on gas-bearing components and screw connections,
Keep components of the gas system away from direct heat (e.g. incident solar radiation) and avoid temperatures in excess of 60 °C/122 °F – risk of explosion. No repair operations in which temperatures in excess of 60 °C/140 °F may be encountered (e.g. during paint drying in the combined spray / drying plant or in the paint dryer) must be undertaken unless the vehicle's pressurised gas tanks have been removed and the other gas system components completely discharged and flushed with inert gas. If it is necessary to flush the gas system, only inert gases may be used which do not constitute an ignition hazard. An example of a suitable inert gas is nitrogen. Gas system components such as the pressure reducer must never be subjected to heat; the changes to the material properties that may occur can have a considerable effect on the operating safety of the vehicle. The gas system components must therefore not be thawed out using an external heat source if they freeze up. Pressurised gas tanks, gas lines and all parts carrying gas must always be removed if work is being carried out during which extreme heat will be generated such as cutting work, grinding work, soldering work and welding work, working with hot air or cutting torches etc. within a distance of 1 metre or less of these parts. All other gas system components must be completely discharged and flushed with inert gas. Never install connections with missing closures, or parts that have been impregnated with dirt, grease or moisture. Never install pipes, hoses and individual components unless the connections are in perfect condition. Gas system components which must be loosened or removed during repair work must be properly refastened in their original positions using genuine Aftersales parts (cable ties, clips, wiring trough brackets, etc.). Particular care must be taken regarding proper routing and secure connection of gas-bearing components. No other components must be fastened to gas lines, e.g. wiring. Before reusing the vehicle after repair work, the gas system must always be subjected to a leak test, as described in the Service Instructions. Following assembly, the natural gas system must not suddenly be subjected to natural gas under full operating pressure from the pressurised gas tanks, e.g. due to the opening of a solenoid valve. It would then not be possible to find a leaking connection using the usual leak-detecting sprays as, due to the high pressure of 200 bar, the natural gas would blow away the leak-detecting medium from the leak point without the formation of bubbles. Due to the high pressure, leaks constitute an injury hazard. Furthermore, all gas system components must be subjected to a functional and visual check with regard to defects such as contamination, deformation, formation of cracks, chafing, corrosion and other damage. As cut-off devices with actuators (solenoid valves) are used, the switching function must be checked. The cut-off devices must close automatically when the ignition is switched off (audible). Soiled parts must be cleaned and protected from ageing with suitable anticorrosives if necessary (not oil). Vehicles in which leaks in the gas system have been detected must not be handed over to the customer – danger of explosion. Malfunctions or faults which are detected in the gas system must be remedied immediately. Filling a natural gas-driven vehicle using a system without a gas dryer and without a filter is impermissible. Switch off the engine and the auxiliary heater before filling the pressurised gas tank system. The vehicle to be filled must be protected against rolling by engaging the parking brake. Important: Servicing and repair work on the gas system is subject to mandatory registration, see Section 7.6. Escaping gas can cause injury and freezing to parts of the body with which it comes into contact. If necessary, suitable protective measures must be taken, such as the wearing of protective leather gloves. Appropriate warning signs must be set up during operations on the gas system. Lift and support the vehicle at the designated jacking points only. The jacking points on the body are vehicle-specific, are listed in the Service Instructions in group "A" and must be observed. It is not permissible to lift the vehicle at certain components, e.g. pressurised gas tanks, carrier frame for pressurised gas tanks etc., as slipping of the vehicle could cause damage to the pressurised gas tanks or the high pressure lines. Spraying or other application of oil or lubricants in the vicinity of gas system components is prohibited – danger of explosion. Utmost cleanliness must be ensured during operations on the gas system, especially with regard to the screw connections of gas-bearing components. The work must be performed with the utmost care. For cleaning purposes, only use:
Several operations require special service tools that may only be utilised for the purpose specified in the Service Instructions. The use of these tools ensures safe and technically reliable repair work, as approved by Opel/Vauxhall.
7.3 Workplace Since the technical safety equipment of the maintenance areas is inadequate for working on the gas system with the release of gas that may occur, vehicles with leaking gas systems must not be brought into the maintenance area. These vehicles must be parked in the open with adequate protection. Do not empty gas system components in confined working areas. Action in an emergency: Vehicle with defective gas system at dealership: Vehicle remains in the open. If work must be carried out on the gas system itself, before beginning any work ensure that no hazardous, explosive atmospheres can arise in the work area (limit build-up). Always ensure that there is adequate aeration and venting in the workshops. Adequate aeration means that the air in the work area must be exchanged at least 3 times per hour. However, the corresponding venting rate must be worked out by architects for each case. A waiting period is stipulated for vehicles with damaged gas systems which have not been closed off. This waiting period is, as a minimum, the length of time it takes a gas system filled to maximum to drain. During this waiting period, the vehicle should be placed in the yard, on the area set aside and approved for the emptying of gas tanks. Suitable protective clothing must be worn when working. Venting the natural gas: Venting the natural gas system into the open (venting the natural gas) and inerting the natural gas system must be carried out on marked (e.g. cordoned off with tape) or separate open areas. Measures must be taken to prevent electrostatic discharge. The leakage resistance of the floor must be <10 8 Ohms. The area must be protected from lightning. An emptying ban during storms would be an alternative. No-one must go near the vehicle during and just after emptying. All emptying must take place with a cold engine/exhaust system. Ignition sources are prohibited within 5 metres of the blow-off source. This includes work such as welding, cutting, disconnecting and hammering work. Draining liquid gas: There are various methods of tank drainage.
In all methods, a safety zone must be set up which may vary. The place for erection of the safety zone must be selected so that no gas can penetrate remote buildings, e.g. via open windows and doors. The place must also be easily accessible and well ventilated. When draining liquid gas, ensure that the place has a safety zone of at least 10 metres radius which may be extended if necessary. The safety zone must be fenced off in a manner which is clear to everyone. The place must have no recesses or depressions as liquid gas can collect here.
7.4 Components Because type-approved parts are assigned to the vehicle by registration number, gas system parts that require registration must be documented in the vehicle's Check Booklet when they are replaced. (see section 7.6 entitled Registration). Gas system components such as (e.g.) the pressure reducing valve, are sensitive to impact. The installation of gas system components which have fallen onto the ground is prohibited. Strict observance of the use of materials and additives (such as approved assembly pastes) is required for certain operations in the Service Instructions. Only those replacement parts approved and released for the relevant vehicle may be used in the gas system. This is assured by the use of Opel/Vauxhall parts. Other parts may not be used, as these are not type approved and result in the cancellation of the type approval. The connections of gas system components must be sealed immediately after removal using tight-sealing closure caps. In warranty cases, returned components which have not been sealed cannot be accepted. Remove new parts from their packaging immediately prior to installation and check visually.
7.5 Transportation and Storage Pressurised gas tanks with carrier frames / gas tanks may only be transported / returned if the following conditions are fulfilled:
The gas tanks in vehicles that have been involved in accidents and are not going to be repaired must be removed and disposed of in accordance with the stipulations of the country-specific laws. For vehicle repairs requiring longer periods of time, removed, non-flushed pressurised gas tanks must be stored under lock and key. Storage with other hazardous materials (e.g. paint) is prohibited. The storage area must identified with the corresponding hazard symbol and must be suitable for this purpose in accordance with national legislation. The stipulations of national legislation and hazardous goods legislation must be observed. For transportation by means of road vehicles, pressurised gas tanks must be stored in such a way that they cannot tip over, fall off or shift their position. For the transportation of pressurised gas tanks, only those lifting devices may be used which reliably preclude damage to, or dropping of the pressurised gas tanks. Inerting the system The system which has been depressurised from its normal pressure is then pressurised once with nitrogen at a pressure of 15 bar and discharged; it is then pressurised with nitrogen again in a second cycle, this time at a pressure of 10 bar, and discharged (depressurised) again.
7.6 Registration All maintenance and repair work carried out on the gas system must be entered in the vehicle's Check Booklet. Continuous proof of conformance to all maintenance and repair schedules for the vehicle is required. Statutory legislation stipulates the storage of workshop documents for gas-powered vehicles over a period of 10 years. It must be ensured that this data can be retrieved if required. The following registered components are installed in CNG-driven Opel vehicles:
The following registered components are installed in LPG-driven Opel vehicles:
Components that have to be registered bear an EU qualification approval number / ECE number. All work on the CNG gas system must be entered in the vehicle's Check Booklet (additional instructions – monovalent plus – LPG / GPL) / service booklet. After installation of registered components, the dealer must enter the following information in the vehicle's Check Booklet: What was done; by whom; at what mileage reading; which registered components were replaced. In principle, only gas components with an ECE approval may be fitted.
|
||||||||||||||||
