Chemical Product

Design:

HEALTH AND SAFETY OF GAS FUEL

ANIMATION VIDEO
(Assignment 1)

By: Group 20 (Chemical Engineering)

Danny Leonardi
Maria Ulfa
Rahmatika Alfia
Raudina
Rayhan Hafidz

CHAPTER 1
Background

Background
Fuel gas consumption in
Indonesia still growing
The government
policies for conversion
the fuel oil to fuel gas

 The accidents that

caused by use of the
fuel gas is still going
on

 Most of these
accident occur to
the poor installation
condition of fuel gas
and the lack of
knowledge to use it

 It is necessary to
socialization about
how to use fuel gas
properly and safely
for the general public

 Animation video can socialize how to

use fuel gas properly and safely with
the attractive and simple way to be
easy to understand by public

CHAPTER 2
Review of Literature

Hazard of Fuel Gas

Liquefied
Petroleum Gas

Compressed
Natural Gas

Hazard of Liquefied Petroleum

Gas (LPG)

Physical
Hazard
Health
Hazard

Physical Hazard
LPG in gas form = 2 x air
Tend to sink and accumulate in lower
parts of container
LPG in liquid form cold burns to the
skin because its rapid vaporization
Forms flammable mixture with air in
concentrations 2% - 10%
Fire and explosion hazard if stored and
used incorrectly
Vapor/air mixtures can be ignites from
distance and travel back to the source
of leak and explode
At high concentrations asphyxiant
gas

Health Hazard
Routes
of
exposure:
inhaled, eyes contact, skin
contact
Overexposure:
cause
lightheadedness
and
drowsiness,
even
unconsciousness and death
In liquid form: frostbite and
irritation
OSHA standard: 1000 ppm
in 8 hour work-shift

Hazard of Compressed Natural

Gas (CNG)

Physical
Hazard
Health
Hazard

Physical Hazard
High pressure storage creation of a
fire hazard, high velocity ejection of
metal parts
Ignition of leaking natural gas near the
source create flame
Small volume of gas accumulate
reduce danger
When
leaks

container
will
overheated, causing smoke and fumes
Large fuel leaks large cloud of
flammable mixture
Ignition of mixture potential
explosion and subsequent fire

Health Hazard
One of the safest transport fuels
Odorized prior to distribution
easier leak detection
No known toxic or chronic
physiological effects
Exposure to moderate concentration
headache (rarely happens)
Natural gas < air enhance safety

Data and Statistic of Fuel

Gas Accident

Data and Statistic of LPG

LPG Accident Data

(Source: National Consumer Protection Agency)

Data and Statistic of LPG

LPG tank and components are not
fulfill the requirements, such as:
7% of total LPG 3kg tank
20% of regulator
50% of gas stove
66% of tank valve
100% of hose
Information only distributed to distributor
and not retailer and consumer

Data and Statistic of CNG

In 2015: more than 15 cases of
Transjakarta bus is on fire
In 2016: at least 2
Those accidents are not caused by CNG,
because it is on fire, not explode.

Countermeasures of
CNG and LPG Accident

Countermeasures LPG Accident

1.
2.
3.
4.
5.

Gas tube placement

Installation of gas cylinders
Prior to the use of LPG gas stove
If there is leakage of LPG gas
If fire occurs in the accessories (hose,
regulator)
6. Maintenance tube

Before use, storage tanks of CNG

through several tests, as follow:
Bump test
Bonfire Test
Gunfire Test

Countermeasures of CNG
Accident
CNG
Proper maintenance with the right preventive
inspection
Proper thermal insulation in the engine
areas of potential sources of fires designed and
installed properly
using high-grade electrical components
training for bus drivers and crew in handling fires
using fire detection systems, automatic fire and
manuals that are reliable and correct selection
insulation system that auto fuel breaker in the
event of leakage both in situations of normal
operation and in case of accident

CHAPTER 3
Real Life Problem

Common Mistakes by
People

LPG

1. Bad
Habits

Peoples/Food traders
often change their gas
and open the regulator while the fire is still
burning in their stove
They light their cigarettes when changing
the fuel gas
They dont check whether they have
installed the equipment LPG correctly

Equipments failure:
a. Regulator
Peoples dont realize that their regulator
have a poor quality
Some regulator dont even have SNI
standard
This kind of regulator doesnt cover the
tube well

b. Hose
Its not only because of the hose that
maybe have a poor quality
Also by the bite of rats.
The risk of this deteoriation by the rats is
high enough, because people must have
placed LPG at the bottom

3.
Ventilation
Ventilation installation can
prevent the gas to be
accumulated

Chances of explosion could increase if the room isnt

fitted with proper ventilation installation
A good ventilation installation when using LPG at not
only on the top, but also at the bottom of the room

CNG
Electricity System
Commonly, the broken electricity system happens
in the room of battery/accu, alternator, or AC
compressor.
Friction
In
the tyres
because of its leak, or the worn-out
Engine
components
brakes
Because the leak of fuel
gas, lubricants, rupture
in
exhaust/turbocharger,
or overheated
components.

Current HSE Publication

of Fuel Gas

 Television

 Poster

 Direct socialization

Implementation of
Regulation

LPG

The common implementation of LPG

regulation target by the government:
Producer
Distributor
Consumer

The authorities that have a right to

regulate the regulation of the LPG and
CNG:
Central government (Pemerintah RI)
Province government (Pemprov)
District or city government (Pemkab
or Pemkot)

For direct supervision, its due by the

inspectors of HSE, specialist of steam
engines and pressure vessels.

 The implementation must have a 3 principle:

Preventive, systematic, and comprehensive
Regulations must cover:
1. Plan and design
2. Production and manufacture
3. Installation
4. Selling
5. Usage and maintenance
6. Reparation and modification

LPG Distribution
Channels

Regulation Trade of LPG

The examples of the SNI standard in LPG

equipment are:
SNI 1452-2007 for LPG Steel Tube
SNI 7369-2007 for LPG Regulator
SNI 15-1591-2008 for LPG valve
SNI 06-7213-2006 for LPG hose

Community of LPG
Channel
Duty of Community of LPG Channel:
1. Monitoring the use of LPG in their
territories
2. Reporting field conditions and do
counselling
3. Reporting incidents or accidents
4. If the incidents or accidents
happens, the community is
looking for the information about:
. The cause of the incidents or
accidents
. Condition of the victim
. Damage to the buildings
. Chronology of the incidents or
accidents

CNG

The target of CNG safety regulation:

Users (drivers, etc.)
Providers, such as the owners and
the staffs of fuel gas station (SPBG).

For the Users

The government test the fuel gas vehicle to
the standard.

When the vehicle passed the test, the vehicle

will be given the permission to be ridden.

For the Providers

For the SPBG owners and staffs, the
government will be given correct and
safety CNG technical.
The government also take standardization
to the garage of fuel gas vehicles.

CONCLUSION

The type of fuel gas that is often to used is LPG

(Liquefied Petroleum Gas) and Natural Gas in
the form of CNG (Compressed Natural Gas).
The government has set the regulations of use
of LPG and CNG as well as any system that
supports the installation of that fuel usage.
Most accidents that occur on BBG usage were
caused by the public ignorance to use it
properly and safely.

The socialization of the use of fuel gas

properly and safely is really need to do.

The animation video of health and safety

on gas fuel usage is one of alternative to
socialization, because it can be more
interactive and easily to spread through
many media.

TERIMA KASIH

Problem Definition

Many
accident that
occur due the
use of fuel
gas

Lack of public
knowledge about
how to use the
fuel gas properly
and safely

Animati
on
Video of
Fuel Gas

The
governments
program that
require
increasing the
use of fuel gas in
the country

Identification of Problem
The needs of efforts
to socialize the
information about
how to use fuel gas
safely for the
peoples widely in a
creative ways and
easy to understand.
The efforts from the
government to make
socializations and
regulations to
Animati
prevent the fuel gas
accident are still low
on
and poor.

The lack of peoples

awareness and
knowledge about
how to use fuel gas
safely that can
prevent the
accidents.
In Indonesia, a
number of
accidents
because of the
use of fuel gas
are still high.

Video of
Fuel Gas

Limitation of Problem
This animation
video is designed
with a cute
characters and
interesting plot
This animation
video is
designed for
the citizens and
peoples

The contents
explain the fuel gas
combustion (with
easy explanation)
and how to use the
fuel gas with safety
aspect

Animati
on
Video of
Fuel Gas

This animation
video is focused to
explain about LPG
and CNG

Definition
of
Fuel
Gas
can chemically
react
with oxygen
and produce heat energy

can be found in large quantities in

nature

can be transported and stored

has an acceptable price

the products of its chemical

processes pollute the environment
within reasonable limits

Solid

Fu
el
Gaseo
us

Liquid

Fuel

Commerc
ial
Waste

Natural
Gas
Liquified
Petroleu
m Gas

Produce
r Gas

Comm
on Fuel
Gas

Blast
Furnace
Gas
Coke
Oven

Liquified Petroleum Gas

gaseous at normal atmospheric
pressure
condensed to the liquid state at
ambient temperature and moderate
pressures
The chief constituents are propane
and butane
LPG vapour is denser than air

Detection and Storage of

LPG
Detecti
on

odor from mercaptan

give vent for the ground level

where LPG is stored
should not be stored in cellars
Storage or basements

Composition and Vapor

Pressure of LPG
Propane:
80%

liquid volume

bar (abs) at 20oC

Butane: 20%
bar

liquid volume

Gross Calorific Value (GCV) and

Densities of LPG
Propane: 50.3 MJ/kg
Butane: 49.5 MJ/kg
LPG(80P:20B): 49.6 MJ/kg
per weight or per liquid
volume

LPG(50P:50B): 49.8 MJ/kg

Densities(80P:20B) : 0.524 kg/l
T=15C
Densities(50P:50B): 0.545 kg/l

Flammability and Flash Point of

LPG

Flammability
2.15% - 9.6% of the total
LPG/air mixture

Flash Point
-104C

Natural Gas
consists of hydrocarbons with a very low boiling point
main constituent is Methane (95% of total volume)
other components are Ethane, Propane, Butane,
Pentane, Nitrogen, Carbon dioxide, and traces of other
gases
a high calorific value fuel requiring no storage facilities
mixes with air readily
does not produce smoke or soot
no sulphur content
lighter than air
disperses into air easily in case of leak

Composition
Component

Fuel Oil

Coal

Natural
Gas

Carbon

84

41.11

74

Hydrogen

12

2.76

25

Sulphur

0.41

Oxygen

9.89

Trace

Nitrogen

Trace

1.22

0.75

Ash

Trace

38.63

Water

Trace

5.98

Compressed Natural Gas

Flammability

Flash Point

concentrations 5%15% when mixed with

air (below 5% or
higher 15% CNG will
not burn)

1100 degrees
Fahrenheit (593.33C)

 Combust
ion
the complete
exothermic oxidation
of a fuel with
sufficient amount of
oxygen or air with the
objective of producing
heat, steam and/or
electricity

Energy produced
Energy transfer, or internal energy or
combonation of them
Evaluate fuels
Based on the fuels heat of reaction
or heating value
Rapid fuel oxidation results
Large amounts of heat
If enough air is present.
Fuel gases will burn
Nitrogen reduces combustion
efficiency
by absorbing heat from the
combustion of fuels and diluting the
flue gases

Reactions and Heat Release

Forming Carbon dioxide
C + O2 CO2 + 8,084 kCals/kg of
Carbon
Forming Carbon monoxide
2C + O2 2CO + 2,430 kCals/kg of
Carbon
Forming Water
2H2+ O2 2H2O + 28,922 kCals/kg of
Hydrogen
Forming Sulphur dioxide
S + O2 SO2 + 2,224 kCals/kg of
Sulphur

Combustion of NG

CH4 +2O2 CO2 + 2H2O

Methane burns, when mixed with the proper amount of air and
heated to the combustion temperature
The process with the amount of air and fuel required for perfect
combustion.
Flue gas from combustion of NG are harmful except water
One kilogram of fuel requires a certain minimum of ambient air
to be fully combusted, called Stoichiometric Air or Theoretical
Air.
Combustion technology help us to ensure the proper amount of
air that minimizes environmental impact and fuel consumption
The theoretical air-fuel ratio is a fuel specific parameter that
shows how efficiently fuel is combusted

Hazard
Identifica
tion

Hazard
Identificati
on

Standard Regulation of Fuel Gas

Usage
Standard Regulation for
Converter Kit
Standard Regulation for LPG
usage
Standard Regulation for CNG
usage

Standard Regulation for

Converter Kit
Ministry of Industry and Trade Regulation
no. 70/M-IND/PER/7/2012
about
Technical Requirements Enactment for
Converter Kit Component System in Vehicles

Clause 2 Converter Kit and Tank Scope

(1) Based on fuel used in Converter Kit and Tank for vehicles, it is divided into two types which are :

Converter Kit and Tank for Vehicles with Compressed Natural Gas (CNG) fuel
Converter Kit and Tank for Liquified Gas for Vehicle (LGV) fuel

(2) At least Converter Kit system should be required with :

1. Converter Kit with CNG fuel
Piping
Regulator
Mixer/injector
Cylinder valve
Isolation valve
Refuelling non-return valve
Refuelling connection
Safety cut-off device
Gas pressure controlling device
Fuel volume indicator
Electronic Control Unit
Electrical wiring for Gas Conversion Component System

2. Converter Kit with LGV fuel

Piping
Regulator
Distribution
LGV filer
Change over switch (on/off)
Volume indicator
Refuelling point
Electronic Control Unit
Shut-off valve/solenoid valve

Clause 2
(3) Converter Kit and Tank as
given in Clause 1 have
number
EX
HS.
8413.30.92.00 which is a
complete converter kit type
for injector and mixer and
consist of components with
Harmonized
System
(HS)
numbers as follows :

Clause 3 Gas Conversion Tank Specification

(1) Compressed Natural Gas (CNG) Tank as given in
Clause 2 is a tank with 200 bar pressure and used in
vehicles as storage of CNG fuel.
(2) Liquified Gas for Vehicles (LGV) that is equipped
with multi-valve as given in Clause 2 is a tank with 20
bar pressure and used in vehicle as storage of LGV
fuel.

Clause 4 Quality Requirements

Converter Kit and/or Tank with CNG fuel and LGV fuel
as given in Clause 2 from domestic or international
market should fulfill the technical requirements and
own product certificate which are :
(1) Economic Commission for Europe R110 and/or ISO
15500 series, ISO 11439, ISO 14469, SNI ISO 1550005-2009, SNI 7407-2009, SNI 7408-2009 for CNG fuel
Converter Kit; or
(2)Economic Commission for Europe R 67 for LGV fuel
Converter Kit.

Standard Regulation for LPG

usage
Directorate General of Land Transportation Regulation
no. SK. 78/AJ/006/DRJD/2008
about
The Usage of Liquified Gas for Vehicle (LGV) in Vehicles

Clause 2
(1) Every vehicle that meets the technical requirements could use fuel gas.
(2) Vehicles that use fuel gas as given in (1) should equipped with fuel gas usage installation system
requirements for vehicles
(3) Usage installation system as given in clause 2 consist of :

BI FUEL system which is vehicle that use fuel gas or gasoline alternately
DUAL FUEL system which is vehicle that use fuel gas and diesel fuel together
FULL DEDICATED ENGINE system which is vehicle that only use fuel gas

(4) Fuel gas usage installation system as given in Clause 2 at least should consist of following
components :

LGV Tank that can equipped with following devices :

80 per cent stop valve

Level indicator
Pressure relief valve
Remotely controlled service valve with excess flow valve
Fuel pump
Multi valve
Gas tight housing
Power supply bushing
Non return valve
Pressure relief valve

Piping

Regulator

Injector/distributor

LGV filter

Change over switch (on/off) for bi-fuel and dual-fuel

Volume indicator

Refueling point

Electronic unit control

Shut-off valve/solenoid valve

(5) LGV usage installation system as given in (4) should fulfill UN ECE R-67 standard

Clause 3
Fuel gas usage installation system as given in Clause
2 (2) should fulfill the following requirements :
a. Administrative
b. Technical

Standard Regulation for CNG

usage
Ministry of Transportation Regulation
no. PM. 39 year 2012
about
The Usage of Compressed Natural Gas (CNG) in
Vehicles

Clause 2
(1) Every vehicle use CNG fuel and operated in streets
should meet the technical requirements
(2) Vehicle as given in (1) should equipped with fuel gas
usage installation system
Clause 3
(1) Fuel gas usage installation system as given in Clause 2
(2) consist of :
Bi-fuel system
Dual fuel system
Full dedicated engine system

(2) Bi-fuel system as given in (1) is used for vehicle that

use fuel gas and
gasoline alternately.
(3) Dual fuel system as given in (1) is used for vehicle that
use fuel gas and diesel fuel together.
(4) Full dedicated engine system as given in (1) is used for
vehicle that only use fuel gas.

Clause 4
(1)
Fuel gas usage installation system as given in
Clause 3 at least should
equipped with following
components :
Fuel gas tank
Piping
Regulator
Mixer
Cylinder valve
Isolation valve
Refueling non-return valve
Filling joint
Automatic shut-off device
Gas pressure controlling device
Electronic fuel gas volume indicator
Electronic control device and cables

Clause 4
(2) Components as given in (1) f, g and h could also be a
group in a device or installed separately
(3) In terms of bi-fuel type usage, automatic shut-off
device as
given in (1) i should use high pressure gas
lock component
and petrol lock off device
(4) In terms of dual-fuel and full dedicated type usage,
automatic shut-off device as given in (1) i only use
high pressure gas lock.

Clause 5
Fuel gas usage installation system should fulfill the
following requirements :
a. Administrative
b. Technical

Calorific Value
Fuel
Gas

Relative
Density

Higher
Heating Value
kcal/

Air/Fuel Ratio
of air to of
Fuel

Flame
Temp.

Flame
Speed
m/s

Natural
Gas

0.6

9350

10

1954

0.290

Propane

1.52

22200

25

1967

0.460

Butane

1.96

28500

32

1973

0.870

Gas tube placement

The room should be open and have
good air circulation
Placed an air vent at the bottom
near the LPG gas cylinder placed
LPG gas cylinders must always be
perpendicular and protected from
solar thermal

Installation of gas cylinders

Make sure the LPG cylinder does not
leak and broken
Tighten the clamp on the stove and
regulators at both ends
rubber hose that will be installed on the
LPG cylinder.
Players / gas stove knob should be
turned off when connecting a gas stove
with LPG cylinder
Remove the plastic seal on the valve
LPG cylinder

 Before installing the regulator on LPG cylinder

valve, knob position must be horizontal.
Regulators must not loose or easily detached.
Turn 90 regulator knob clockwise (to right)
until the knob position to vertical /
perpendicular, so that LPG gas flowing to the
gas stove.
Gas stove should be placed on the flat and
away from flammable materials

Prior to the use of LPG

gas stove
Make sure the LPG cylinder in an
perpendicular position
Make sure the regulator on LPG cylinder
valve has been locked
Check the gas stove, hoses, clamps and
regulators and make sure there are no leaks.
Hoses must be protected from heat and
should not be crushed by any objects.

If there is leakage of LPG gas

There will LPG odor
Remove the regulator
Bring LPG cylinder out of the room /
out of the house and put it on the
ground / open space
Do not ingnite a fire or turn the
power supply

If fire occurs in the accessories

(hose, regulator)
Remove the regulator of the LPG
cylinder while it possible
Bring LPG gas cylinders and other
reserves to a place far away from the
location of the flame.
Put out the fire using a wet burlap
sack or with a small fire extinguisher
type of CO2 or dry chemical

Maintenance tube
Protect the markings on the tube which is the
identity of the gas cylinder
Do not use the top gas tube as a place to put
objects or household material.
If gas cylinder is leaking, brought the gas cylinders
into the open space and away from sparks or heat
or electricity. Do not try to fix it yourself.
There may not mix gas in the gas cylinder or try to
recharge the tube itself. Always contact a
competent supplier of gas cylinders.
Can not be hit and banged gas cylinders