LPG-2 Propane Technician Training Manual State of Oklahoma College of the Desert West Virginia University LPG-2 Propane Technician Training Manual his training manual was created through the hard work and dedication of many organizations and Tindividuals. In 1979 the National Propane Gas Association (NPGA) published an installation and service guidebook: LPG Gas Carburet i o n , commonly known Guidebook 6 . This document was rev i s e d and republished in 1984. The author was Larry Carley. In early 1992, Robert Mahle, a member of the NPGA’s Engine Power Committee, created an ad hoc committee (the Propane Engine Fuel Standards Committee) to revise Guidebook 6 addressing changes in propane motor fuel technology. Combining personal funds with funds from the Office of Transportation Technologies (U.S. Department of Energy ) and Algas Carburetion, Mr. Mahle assembled a cross section of industry and education professionals to pr oduce the first draft of LPG-1. Those individuals are as follows: Dwayne French, Robert Mahle, Colin Me s s e r , Robin Parsons, Bill Pinkerton, Jim Smart, Jim Stout, Roger Wheeler, and Ken Williams. The final pr oduct, LP G - 1 , contains seven chapters and is currently sold and distributed by the NPGA. In 1994, the State of Oklahoma Committee of Alternative Fuels Technician Examiners, College of the Desert, American Society of Advanced Fuel Technologies (ASAFT), and the Wes t e r n Gas Association developed a partnership to produce a curriculum based on LPG-1. The State of Oklahoma prov i d e d Pe t r oleum Violation Escrow Account funds to the Energy Technology Training Center at College of the Desert to write the curriculum. Additional funds were provided by ASAFT, Wes t e r n Gas Association, and Advanced Transportation Technologies Initiative of the California Community Colleges with financial support from the Department of Defense. During the project period, West Vir ginia University received a grant from the U.S. Environmental Protection Agency to produce a similar work. Rather than duplicating ef forts, it was agreed that the project could be done collaboratively; WVU would develop materials specifically for trainers — the instructor notes, pre-and post-tests, student work sheets, overhe a d tr a n s p a r encies, and lab activities. Thanks should also be given to Executive Committee members Robert Mahle, Colin Messer, Robert Myers, William Platz, and Jason Smitherman. Special thanks to Technical Review Committee members Don Bass, Greg Huffman, Fred Moreno, Robin Parsons, Alan Smith, and Roger Wheeler. The LPG 2 Propane Vehicle Training of Trainers program is offe r ed by the National Alternative Fuels Training Program, a project of the National Center for Coal and Energy Research at West Virg i n i a University, administered by Dr. Richard Bajura. The WVU Department of Technology Education is responsible for curriculum development for the Program, as directed by Dr. David McCrory and Dr. George Maughan. Thanks to graduate assistants Steve Macho, Daniel Van Epps, Kimberly Kavanagh, and Douglas Eckert. Also, thanks to graphic artists Karen Norwood, Brian Caudill, Brandon Vallorani, Ter r a h Kelso, and John Hilgerdt. Many thanks to the staff at the NAFTP, including William “Bill” McGlinchey and Albert “Butch” Schrier. Special thanks to Richard “Dick” Riley of Suburban Propane, Bridgeport, OH, and Brian Memmott for their generous contributions to the Prog r a m . This document is ref e r r ed to as LP G - 2 . Its completion is made possible by the dedication of many volunteers and supporters from academia, government, and industry. Additional copies are available fr om the following source s : Colin Messer, Direc t o r Jeanie Robards National Alternative Fuels Training Prog r a m En e r gy Technology Training Center State of Oklahoma Committee of West Vir ginia University College of the Desert Al t e r native Fuels Technician Examiners 1460 Earl Core Rd. 43-500 Monterey Ave n u e 3301 N. Santa Fe Mo r gantown, WV 26505 Palm Desert, CA 92260 Oklahoma City, OK 73118 (304) 293-7882 (619) 773-2596 (405) 521-4687 Thanks to artist Peter Aschwanden of Santa Fe, NM, for the Professors and Dingbats that adorn this manual. Layout, production and editing by John Hilgerdt, Access Publications, 86 1/2 N. Lexington Avenue, Asheville, NC 28801, 704-252-6588. Many special thanks to Judy Wolgamott, Office Manager, ETTC. Liquefied Petroleum Gas Training Program Liquefied Petroleum LPG-2 PROPANE TECHNICIAN TRAINING MANUAL Gas CONTENTS - MODULES MODULE 1: PROGRAM PURPOSE & OBJECTIVES MODULE 2: OVERVIEW OF ALTERNATIVE FUELS MODULE 3: PRESSURE AND MEASUREMENT MODULE 4: PRINCIPLES AND PROPERTIES - FUEL THEORY MODULE 5: LEGISLATIVE AND REULATORY POLICIES MODULE 6: BASIC COMBUSTION THEORY MODULE 7: BASIC EMISSIONS AND CONTROLS MODULE 8: LPG FUEL SYSTEMS OVERVIEW THEORY MODULE 9: SAFETY AND REGULATIONS MODULE 10: VEHICLE COMPATIBILITY ANALYSIS MODULE 11: EQUIPMENT LAYOUT & DESIGN MODULE 12: FUEL TANK INSTALLATION MODULE 13: FUEL SUPPLY LINE & INSTALLATION MODULE 14: CONVERTER INSTALLATION MODULE 15: AIR VALVE MIXER & FUEL INJECTION INSTALLATION MODULE 16: ELECTRICAL WIRING, CONNECTIONS, PROTECTION, & ROUTING MODULE 17: FUEL SWITCHING & LEVEL MONITORING MODULE 18: ELECTRONICS INTERFACE MODULE 19: AIR INDUCTION MODULE 20: TANK PURGING & LEAK CHECKING MODULE 21: POST CONVERSION - VEHICLE PERFORMANCE MODULE 22: DRIVER ORIENTATION MODULE 23: FACILITY SAFETY MODULE 24: FUELING STATIONS MODULE 25: TRAINING THE TRAINER GLOSSARY Liquefied Petroleum Gas Training Program 1 MODULE 1: Program Purpose and Objectives State of Oklahoma College of the Desert West Virginia University Liquefied Petroleum MODULE 1: PROGRAM PURPOSE AND OBJECTIVES Gas CONTENTS OBJECTIVES.......................................................................................................1-i INSTRUCTOR NOTES .........................................................................................1-ii THE FOCUS OF THE PROGRAM.........................................................................1-1 STRATEGY FOR TECHNICIANS ..........................................................................1-1 OVERHEAD TRANSPARENCY MASTERS HANDOUT: SUBURBAN PROPANE: SOME STRAIGHT TALK ABOUT GASEOUS FUELS PAGE 1-i Liquefied Petroleum MODULE 1: PROGRAM PURPOSE AND OBJECTIVES Gas OBJECTIVES At the completion of this module, the technician will be able to: • Describe the purpose of the program and how they can benefit from its training. • Identify strategies for learning the program’s content and training. Liquefied Petroleum Gas Training Program PAGE 1-ii Liquefied Petroleum MODULE 1: PROGRAM PURPOSE AND OBJECTIVES Gas INSTRUCTOR NOTES INSTRUCTOR MATERIALS/MEDIA NEEDED Overhead projector or LCD panel/projection equipment Overhead transparency masters or Microsoft PowerPoint 4.0 presentation file Mod2.ppt Note: Slides correspond to text as indicated by icon VCR with TV or projection unit Videotape Segment:NATEF Career Encounters - Alternative Fuels Vehicle Technician, 15:00 or 28:30 minute versions Note: Videotape segments correspond to text as indicated by icon Handouts: Suburban Propane: Some Straight Talk About Gaseous Fuels Note: Handouts correspond to text as indicated by icon STUDENT MATERIALS/MEDIA NEEDED Module 1: Program Purpose and Objectives OVERHEAD TRANSPARENCY MASTERS The printouts enclosed with this module are taken from the Microsoft PowerPoint 4.0 presentation file Mod1.ppt . Instructors planning to use overhead projectors should make transparencies from these printouts on a copier (or laser printer designed to safely print to acetate. Note: Please review Module 25: Training of Trainers for more hints on instructional needs and strategies. Liquefied Petroleum Gas Training Program PAGE 1-1 Liquefied Petroleum MODULE 1: PROGRAM PURPOSE AND OBJECTIVES Gas THE FOCUS OF THE PROGRAM Key Points & Notes Public concern for the environment, our nation’s fuel dependency, and the enactment of federal and state clean air initiatives are 1-2 spawning a national alternative fuel industry -– an industry that is becoming vital to our energy security and environmental well-being. Suburban Propane: Some Straight Talk For this industry to grow, skilled technicians must be available to About Gaseous Fuels service the new vehicles. The training program you are attending includes training methods and materials for the conversion and servicing of vehicles fueled by propane. Through training, the NATEF Career program will enlarge the pool of skilled technicians and thereby Encounters: Alternative support broad-scale adoption of alternative fuel technologies. Fuels Vehicle Technician This model approach to delivering training in vehicle conversion, maintenance, safety, and emissions testing has been developed by a multidisciplinary team. The program is instructionally sound and is comprised of easily applied modules that are useful for field use. STRATEGY FOR TECHNICIANS READ THE OBJECTIVES Each module begins with a list of objectives intended to give the technician an idea of the scope of the module and to focus on the 1-3 main concepts that should be learned. This is very important because they are what will be tested for later. The objectives are stated in roughly the same order in which they a re covered in the module. Some are concerned with understanding important concepts. These objectives usually require the technician to state the concept and describe or explain it. Other objectives call for applying what has been learned. They usually state the conditions under which