1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirelyvoluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefro
2、m, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.TO PLACE A DOCUMENT ORDER: +1 (724) 776-4970 FAX: +1 (724) 776-0790SAE WEB ADDRESS http:
3、/www.sae.orgCopyright 2002 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.SURFACEVEHICLE400 Commonwealth Drive, Warrendale, PA 15096-0001RECOMMENDEDPRACTICEJ2406ISSUEDMAR2002Issued 2002-03Recommended Practices for CNG Powered Medium and Heavy-Duty TrucksForewordThis SAE R
4、ecommended Practice is intended as a guide for standard practice and is subject to changein order to keep pace with experience and technical advances. Its purpose is to promote safety and efficiency bymaking available to sellers and buyers of commercial compressed natural gas (CNG) powered medium an
5、dheavy-duty trucks (TRUCKS) a recommended practice for construction, operation, and maintenance of suchTRUCKS. (TRUCKS defined as vehicles with a gross vehicle weight (gvw) of greater than 6350 kg (14001 USApounds.) The intent of this document is to cover TRUCKS only and specifically excludes passen
6、ger vehicles suchas: buses, recreational vehicles, motor homes or vehicles which may incorporate a TRUCK chassis in theirconstruction.This document was developed by the SAE J2406 Committee, which was organized in 1998 to guide the truckingand NGV industries in their efforts associated with the use o
7、f CNG as an alternate fuel for use in medium andheavy-duty trucks. Prior to the first meeting, preparatory work for this recommended practice was built upon thestrong foundation established by the Truck Engine - Chassis Manufacturers LNG Technical Subcommittee of theATA Foundations Alternative Fuels
8、 Task Force in developing SAE J2343 Recommended Practices for LNGPowered Heavy Duty Trucks.The first steps of the SAE J2406 Subcommittees work included (1) Review of the Modes and Effects Analysis(FMEA) - SAE J2343, (2) detailed review of existing codes, standards, recommended practices, and regulat
9、ionspertinent to trucks and CNG in force or in preparation. It is the intent of the SAE J2406 Recommended Practicesto reference and follow the path of the SAE J2343 Recommended Practices whenever and as closely as possible.The content and format for SAE J2406 will utilize the content, FMEA and pract
10、ices from the SAE J2343 documentas it applies to compressed natural gas applications for TRUCKS.Although a separate FMEA was not conducted for this document, the committee did make use of the applicablesections from the original SAE J2343 FMEA documentation. The SAE J2343 committees original work be
11、ganwith a FMEA for LNG onboard fuel systems, facilitated by Failure Analysis Associates. This study identifiedFailure Scenarios and Failure Mechanisms, which could potentially lead to the identified Failure Scenarios. Thecommittee also recognizes that there are FMEAs that have been performed for aut
12、omobiles and small trucks thatremain within the domain of the owners and were not available to the committee for review.It is the intent of this document to insure the safety and utilization of components for CNG onboard fuel systemapplications whenever possible, i.e., to avoid the potential failure
13、 mechanisms that could be identified, wherepossible, and to devise and recommend means of construction, operation, and maintenance which would warn ofan impending fault or failure, and/or mitigate the outcome should a failure occur. In all cases the CNG onboardfuel system should be consistent and in
14、 conformance with applicable federal, state and local requirements.SAE J2406 Issued MAR2002-2-This publication necessarily deals to some extent in generalities, because it is not possible to anticipate andaddress every individual set of conditions that might be found in constructing, operating, and
15、maintaining CNGpowered TRUCKS. It is intended to be a practical guide illustrating rather than dictating the application of theseRecommended Practices. The correct application of these practices in any field situation must rely on soundjudgment and experience. Whether or not to institute this volunt
16、ary document is up to each individual company,and members of the Subcommittee have not reached any agreement to use it or to require its use.This document does not address the choice of compressed natural gas (CNG) tank(s) or the method of mounting,as this is application specific. In all cases, the
17、choice and mounting of the CNG tanks shall be in accordance withthe chassis manufacturers recommendations. (In conjunction with a CNG tank suppliers recommendations for thespecific application).TABLE OF CONTENTS1. Scope31.1 Purpose 32. References .42.1 Applicable Publications .42.1.1 SAE Publication
18、s 42.1.2 ANSI/IAS Publications 42.1.3 Federal Motor Vehicle Safety Standards 42.1.4 California Code of Regulations .42.1.5 Compressed Gas Association Publications 42.1.6 NFPA Publications .42.1.7 Department of California Highway Patrol - Title 13 Regulations .52.2 Related Publications .52.2.1 Federa
19、l Motor Carrier Safety Administration Publications 52.2.2 Texas Railroad Commision Publications 52.2.3 Canadian Standards Association Publications .52.2.4 Canadian Gas Association Publications .52.2.5 GTI Publications .52.2.6 ASME Publications .52.2.7 Department of Industrial Relations Publications
20、.52.2.8 CCPS Publications .53. Fuel System Components and Definitions 53.1 Maximum Allowable Working Pressure 53.2 Pressure Regulator .53.3 Service Pressure 53.4 Pressure Relief Valves .53.5 Fuel Quantity Indicator 63.6 Pressure Indicator .63.7 Shutoff Valves .63.8 Excess Flow Device63.9 Fuel Tank S
21、upports 63.10 Automatic Shutoff Valves 6SAE J2406 Issued MAR2002-3-4. Fuel System General Design - Construction Considerations64.1 General .64.1.1 Fuel System Cleanliness 64.1.2 Gas Detection .64.1.3 Electrical Requirements64.1.4 Gas Filtration 64.1.5 Defueling Requirements .75. Operation 75.1 Gener
22、al .75.2 Fuel System Overview 75.2.1 Fuel Tank System .75.2.2 Pressure Relief Valves .75.2.3 Automatic and Manual Shutoff Valves 75.2.4 Vent System .75.3 Operational Safety 75.3.1 Leak Detection 75.3.2 Methane Leak Detection Device(s).75.4 Fueling Safety .75.4.1 Grounding For Electrostatic Discharge
23、 .75.4.2 Defueling.75.5 Fuel Quality.85.5.1 Fuel Specifications 85.5.2 Fuel Contamination.86. Maintenance - General .86.1 Final Stage Manufacture.86.1.1 Safety Hazards .86.1.2 Protective Equipment86.1.3 Fuel System Leaks .86.2 Facility and Vehicle Safety During Maintenance 86.2.1 Fuel System Bleed D
24、own .86.2.2 Leak Testing .8 6.2.3 Protection from Ignition Sources.86.3 Fuel System Maintenance Overview 86.4 System Components 96.5 Document Related Resource Information.97. Generic SAE J2406 CNG Fuel System Schematic for TRUCKS.91. ScopeThis SAE Recommended Practice provides guidance for the const
25、ruction, operation, andmaintenance of CNG powered medium and heavy-duty trucks. The intent of this document is to coverTRUCKS (6350 kg (14001 gvw pounds) and above) and specifically excludes passenger vehicles such as:buses, recreational vehicles, motor homes and/or passenger vehicles which may inco
26、rporate a truck chassis intheir construction.1.1 PurposeThe purpose of this document is to establish a uniform practice for construction, operation, andmaintenance of CNG powered TRUCKS and is subject to change to keep pace with experience and technicaladvances.SAE J2406 Issued MAR2002-4-2. Referenc
27、es2.1 Applicable PublicationsThe following publications form a part of this specification to the extent specifiedherein. Unless otherwise indicated, the latest issue of each publication shall apply. Specific documentspertaining to a scope of work are referenced at the end of this document (6.5).2.1.
28、1 SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. (724-776-4790 (ww.sae.org/products)SAE J1703Fuel Systems - Trucks and Truck TractorsSAE J1616Recommended Practice for Compressed Natural Gas Vehicle Fuel SAE J2343Recommended Practice for LNG Powered Heavy - Dut
29、y Vehicles2.1.2 ANSI/IAS PUBLICATIONSAvailable from CSA 8501 East Pleasant Valley Rd., Cleveland, Ohio 44131.(ww.csa.ca) 800-463-6727 or Natural Gas Vehicle Coalition, 1100 Wilson Blvd. STE. 850, Arlington, VA22209 703-527-3022 (kbattengvc.org).ANSI/AGA NGV2Basic Requirements for Compressed Natural
30、Gas Vehicle (NGV) Fuel ContainersANSI/AGA PRD1Pressure Relief Devices for Natural Gas Vehicle (NGV) Fuel ContainersANSI/AGA NGV1Standard for Compressed Natural Gas Vehicles -Refueling Connection DevicesANSI/FCI 70-2Control valve seat Leakage2.1.3 FEDERAL M OTOR VEHICLE SAFETY STANDARDS (CODE OF FEDE
31、RAL REGULATIONS PUBLICATION)Availablefrom Superintendent of Documents, U.S. Gov. Printing Office, Wash D.C. 20402 (www.access/gpo.gov).FMVSS 301 (49CFR571.301)Fuel System integrity FMVSS 303 (49CFR571.303)Fuel System integrity of compressed natural gas vehiclesFMVSS 304 (49 CFRS571.304)Compressed Na
32、tural Gas Fuel Container Integrity2.1.4 CALIFORNIA CODE OF REGULATIONSAvailable from Barclays Law Publishers, Attn.: Client Services, P.O.Box 3066, South San Francisco, and CA 94083. (http:/ccr.oal.ca.gov).California Title 08 - CNG & LNG vehicle regulations2.1.5 COMPRESSED GAS A SSOCIATION PUBLICATI
33、ONSAvailable from Compressed Gas Association, Inc., 1725Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102. 703-412-0900 ().CGA -Pressure Relief Standards S1.1 Part 1 Cylinders for Compressed GasesCGA C- 6.1 Methods for External Visual Inspection of NGV Fuel Containers and their installat
34、ionCGA S1.2 Part 2 Cargo and portable tanks for compressed gasesCGA C - 6.4 Methods of external visual inspection of natural gas vehicle fuel containers and theirinstallation.CGA Pressure Relief Standards S1.3 Part 3 Compressed Gases Storage Containers2.1.6 NFPA PUBLICATIONSAvailable from National F
35、ire Protection Agency, 1 Batterymarch Park, P.O. Box 9101,Quincy, MA 02269-9101.800-344-3555 (htpp:/catalog.nfpa.org).NFPA 52Compressed Natural Gas (CNG) Vehicular Fuel SystemsNFPA 70National Electrical CodeSAE J2406 Issued MAR2002-5-2.1.7 DEPARTMENT OF CALIFORNIA HIGHWAY PATROL - TITLE 13 REGULATIO
36、NSPO BOX 942898 Sacramento, CA94298 CCR Title 13 - Section 934, Compressed Natural GasCCR Title 13 - Section 936, InstallationCCR Title 13 - Section 935, LNG fuel systems2.2 Related PublicationsThe following publications are provided for information purposes only and are not arequired part of this s
37、pecification.2.2.1 FEDERAL M OTOR CARRIER S AFETY A DMINISTRATIONPublications Available from Superintendent ofDocuments, U.S. Government Printing Office, Washington, DC 20402. (www.access.gpo.gov).2.2.2 TEXAS RAILROAD COMMISSION PUBLICATIONTexas administrative code Available from RailroadCommission
38、of Texas, Capitol Station P.O. Box 12967, Austin, Texas 78711-2967 (http:/infor.sos.state.tx.us:80/pum/plsql/readtac$ext.ViewTAC) 2.2.3 CANADIAN S TANDARDS ASSOCIATIONAvailable from Standards Department, 178 Rexdale Boulevard,Rexdale (Toronto) Ontario, Canada M9W 1R3 800-463-6727 (www.csa.ca).2.2.4
39、CANADIAN GAS ASSOCIATIONAvailable from Canadian Gas Association, 55 Scarsdale Road, Don Mills(Toronto), Ontario, Canada M3B 2R3. 2.2.5 GTI PUBLICATIONSAvailable from Gas Technology Institute, 1700 South Mount Prospect Road, DesPlaines, IL 60018 (www.GTI.org).2.2.6 ASME PUBLICATIONSAvailable from Ame
40、rican Society of Mechanical Engineers, United EngineeringCenter, 345 East 47th Street, New York, NY 100172.2.7 DEPARTMENT OF INDUSTRIAL RELATIONSDivision of Occupational Safety and Health - Pressure Vessel Unit1515 Clay Street, Suite 1302 - Oakland, CA 94612 2.2.8 CCPS P UBLICATIONAvailable from the
41、 Center for Chemical Process Safety of the American Institute ofChemical Engineers - 345 East 47th St., New York, NY100173. Fuel System Components and DefinitionsThe following definitions were derived in assembling thisdocument. 3.1 Maximum Allowable Working Pressure (MAWP)The highest pressure which
42、 should be alloweddownstream of the high-pressure regulator. 3.2 Pressure RegulatorAny device used to reduce pressure (independent of flow) exclusive of engine controldevices. Pressure regulators should be incorporated into the fuel system in accordance with the enginemanufacturers recommendation. 3
43、.3 Service PressureThe settled pressure at a uniform gas temperature of 21 C and 70 F and full gascontent. For this document it is defined as the pressure for which the equipment has been constructed for useunder normal operating conditions. The maximum system pressure shall not exceed 125% of the n
44、ominalservice pressure. The individual tank manufacturer defines the service pressure of the CNG tanks. 3.4 Pressure Relief Valve(s)The fuel system should be equipped with pressure relief valves, or pressurecontrol valves, of which are generally located downstream of the high pressure regulator. Rel
45、ief valve setpressures should follow the engine manufacturers recommendations. Relief valve outlets should be protectedfrom fouling by dirt, debris, snow, ice, and/or water.SAE J2406 Issued MAR2002-6-3.5 Fuel Quantity IndicatorEach system should be provided with a fuel quantity indicator, which can
46、be readfrom inside the cab of the TRUCK. The minimum accuracy of plus or minus one-eight of the volume of the fuelsystem is required. Plumbing CNG gas into the cab is absolutely forbidden.3.6 Pressure IndicatorEach fuel system should be provided with a gauge or other means of determining thesystems
47、pressure. Methods of determining fuel system pressure shall be included to allow safe servicing ofthe system, and mounted in such a fashion as to be protected from damage during operation and maintenance assembly and disassembly.3.7 Shutoff ValvesShutoff valves should be provided for each line, whic
48、h supplies fuel to the engine. Shutoffvalves should be located at or near the fuel tank and should be permanently labeled. 3.8 Excess Flow DeviceA method to prevent excess flow should be provided for each line, which supplies fuelto the engine. Excess flow devices should be oriented so as to minimiz
49、e the effect of road vibration on thevalve actuation. 3.9 Fuel Tank SupportsFuel tanks shall be oriented and mounted on the vehicle in accordance with theTRUCK chassis and CNG tank manufacturers recommendation for the specific application.3.10 Automatic Shutoff Valve(s)Automatic shutoff valves should be included in the system and fail closed onloss of actuating power regardless of orientation (i.e., mounted at any angle) or available pressure differential.The automatic shutoff valve should close on lo
