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Operation and Maintenance

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Liquid Biofuels for Otto Cycle

Ethanol

Engine testing/settings
Ethanol is a fuel with higher Octane rating thus the settings and characteristics of the engines are different.

Commodities/spare parts
Special lubricants may be required.
Replacement parts shall be certified for E85 usage. Also tanks shall be alcohol compatible i.e for example made out of Fiberglas.
Not compatible: Zinc, brass, lead, aluminium, terne (lead-tin-alloy)-plated steel and lead-based solder
natural rubber, polyurethane, cork gasket, material, leather, polyvinyl chloride (PVC), polyamides, methyl-methacrylate plastics,
and certain thermo and thermoset plastics.
Compatible with acceptable resistance to ethanol corrosion: unplated steel, stainless steel, black iron, and bronze
non-metallic thermoset reinforced Fiberglas, thermo plastic piping, and thermoset reinforced Fiberglas tanks, Buna-N, Neoprene rubber,
polypropylene, nitrile,Viton, and Teflon

Facility requirements
Sufficient ventilation of the underground pits and maintenance areas is required (More than with diesel)
The exposure limit is 1000ppm.

Safety precautions
The ranking is the same as with gasoline/petrol.
Ethanol filled tanks have an ignitable air-methanol mixture in the temperature range of 4-46°C. Thus no additional energy may be applied (welding, heating to elevated temperatures, sparks..).
Compared to diesel Ethanol ha a higher vapour pressure. Flames are invisible in open sunlight. However Ethanol ignites not as readily as gasoline/petrol and the flame intensity is lower.
The toxicity is smaller regarding to methanol, however ingestion and skin exposure has to be avoided.
After skin absorption wash the skin with soap and rinse with large quantities of water after having removed contaminated clothing.
After eye adsorption flush the eyes with water for at least 15 minutes.
After ingestion have the person lie down, keep him/her warm and do not induce vomiting.
In all cases contact medical personnel - after ingestion immediately.

Extinguishers should be of B,C,BC or ABC type. Foams should be alcohol resistant (ARF).
On board automatic fire extinguisher systems are recommended on the vehicles.

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Electric- and Hybrid Electric Vehicles (incl. Fuel Cells)

In case of Hybrid Electric vehicles with internal combustion engine, please refer to the chapter with the engine type and fuel combination.

Electric System

Engine testing/settings
Normally no adjustments possible.

Commodities/spare parts
Modern electric systems require no physical maintenance. Batteries might be equalised from time to time and the cooling system cleaned.

Facility requirements
In case of charging the vehicles from the grid, the charging stations should be separated and cables and charging equipment should not cross sidewalks or pedestrian traffic patterns.
Older lead acid batteries require room ventilation during charging (Hydrogen formation). The floor shall resist spill of acids.
Water spay or mist shall be avoided near electric equipment.

Safety precautions
Vehicles should be blocked with wheel stops, setbacks or curbs, to prevent from inadvertently driving.
Higher voltages nowadays used in the electric power train require proper isolation of all energized parts.

Here you find more safety tips

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Gaseous Fuels for Otto Cycle

Compressed Natural Gas CNG

Engine testing/settings
Natural Gas is a fuel with higher Octane rating thus the settings and characteristics of the engines are different.
Also all operations should bear in mind that the gas is pressurized.

Commodities/spare parts
Cast iron, plastic, galvanized aluminium and copper alloys exceeding 70% copper are not allowed.
Most important is to prevent intake of compressor lubrication oil into the vehicle tanks by maintenance of the compressor and its filter/coalescers. Spare parts always should be stored with attached dust caps.

Facility requirements
Since CNG is a gaseous fuel ventilation is very important. All devices should be explosion proof. Methane sensors should be coupled to the forced ventilation (long before ignition ration is reached), the building shall be cut of from the grid but all safety equipment shall function and all valves shall be closed with power cut off.

Safety precautions
The fuel system should be depressurized before starting engine maintenance work.
High pressure fittings loosened under pressure could become a missile.
A high-pressure gas jet could result in a gas embolism in the bloodstream.
Ignition sources like open flames and tempering metals shall be avoided.
On board automatic fire extinguisher systems are recommended on the vehicles.

Liquefied Natural Gas LNG

Additionally to CNG gas storage requires a cold place with the possibility to vent of boiling hydrogen.

Facility requirements
Same as with CNG- more sensors required also near the tanks.

Safety precautions
Because the cryogenic storage does not allow to add odorants, leakages should be detected by methane sensors. Depending on the temperature the spilled LNG may be lighter or heavier than air in the first second (in the long run lighter).
Because of the low temperature (-162°C) touching the fuel system or contact with leaked LNG may result in cryogenic burns.

On board automatic fire extinguisher systems are recommended on the vehicles.

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Liquid Biofuels for Diesel Cycle

Ethanol

please see Otto Cycle

Biodiesel

Biodiesel is a biological well decomposable product and therefore classified into the danger class 1.
However, concerning the storing of Biodiesel according to DIN EN 14214 and fuel according to DIN EN 590 nearly the
same legal regulations apply.

Engine testing/settings
Biodiesel is a fuel with higher Cetane rating thus the settings and characteristics of the engines are different.

Commodities/spare parts
Special lubricants may be required and the exchange interval may be shorter. Oil analysis is required to lengthen the intervals.
Replacement parts shall be certified for biodiesel usage. Also tanks shall be biodiesel compatible
Not compatible:
copper, brass, bronze and galvanised materials
(corrosion effects with the result of the formation of metallic soaps)
Compatible
C steel (St 37), aluminium, teflon, fluorinated polyethylene and fluorinated polypropylene

Facility requirements
Ventilation of the underground pits and maintenance areas is required.
For storage tanks see....
To prevent gelling storage tanks shall not be exposed to very low temperatures, a storage at 7°C to 10°C is adequate.
Antioxidants shall be used if biodiesel is stored over a longer period of time (TBHQ)

Fuel quality control
The cold filter plugging point has to carefully observed to avoid problems in winter. Summer qualities have to be avoided.
When blending takes place on site, the blended fuel shall be sampled to assure that the finished fuel is well mixed in a homogeneous product.
When changing the tank content from a different fuel type , the tank shall be drained, cleaned and then inspected.
Tanks not in operation should be inspected each month, so that water build up may be prevented.

Safety precautions
Flashpoint is significantly higher compared with diesel. Neat biodiesel is non toxic and biodegradable.
Biodiesel should not be near heat, spark or flames.
PVC coated gloves and safety glasses are recommended.
On board automatic fire extinguisher systems are less necessary on the vehicles compared with ethanol or CNG.

Straight vegetable Oil SVO

Engine testing/settings
The fuel system and the ignition times are very different to diesel. Engines shall never be started or stopped with cold SVO

Commodities/spare parts
Special lubricants or oil analysis may be required.
The base and acid number of the motor-oil should be checked.

Facility requirements
SVO is non -toxic and biodegradable.

Safety precautions
SVO is non -toxic and biodegradable. However it is inflammable.
On board automatic fire extinguisher systems are less necessary on the vehicles compared with ethanol or CNG.

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