cng fuelling stations for vehicles
TRANSCRIPT
-
7/30/2019 Cng Fuelling Stations for Vehicles
1/72
The Standards Institution of Israel
42 Chaim Levanon Street, Tel-Aviv 69977, Tel. 03-6465154, Fax 03-6412762, www.sii.org.il
//1209129/05/2012
"6236ISRAELI DRAFT STANDARD SI 6236
2012May 2012
ICS CODE:
COMPRESSED NATURAL GAS (CNG) FUELLING STATIONS FOR VEHICLES
This document is a proposal only
http://www.sii.org.il/http://www.sii.org.il/ -
7/30/2019 Cng Fuelling Stations for Vehicles
2/72
Draft SI 6236 (2012)
2
This standard was prepared by an Experts Committee of the following members:
Anatoly Dubov, Armand Abramovici, Daniel Weinberg, Haim Melamed,
Dr. Jacob Dror (convenor), Sandra Moscovich
Coordinators of the Standard preparation: Dr. Richard Marrow
-
7/30/2019 Cng Fuelling Stations for Vehicles
3/72
Draft SI 6236 (2012)
Descriptors:
compressed natural gas, automotive, vehic les, fuel ing, fuel l ing, f i l l ing, s tat ions, fuel
:
,,,,,,
Updating the Standard
Israel Standards are reviewed periodically at least every five years, in order to adapt them to scientific and technological
developments. Users of Standards should ascertain that they are in possession of the latest editions of the Standard
including its Amendments.
A document appearing in the Reshumot (The Israeli Official Journal) as an Amendment may be a separate
Amendment, or an Amendment incorporated into the Standard.
Official Standard
Whether the document or parts of it are Official should be checked. An Official Standard or Amendment (in whole or in
part) takes effect 60 days following publication of the notice in the Reshumot, unless the notice states otherwise for the
effective date.
Standards Mark
A manufacturer of a product complying with the requirements of the
applicable Israel Standards is entitled, after being licensed by the
Standards Institution of Israel, to mark it with the Standards Mark:
Copyright
This Standard or any part of it may not be photocopied, copied or published by any means whatsoever, without prior
permission in writing of the Standards Institution of Israel.
-
7/30/2019 Cng Fuelling Stations for Vehicles
4/72
Draft SI 6236 (2012)
a
TABLE OF CONTENTS
Foreword............................................................................................................................................................... 1
Introduction........................................................................................................................................................... 2
1 Scope........................................................................................................................................................ 22 Normative References............................................................................................................................. 3
3 Definitions................................................................................................................................................. 5
4. Abbreviations ......................................................................................................................................... 10
5 General provisions................................................................................................................................. 11
5.1 Gas compressor................................................................................................................ 11
5.2 Gas storage...................................................................................................................... 11
5.3 Mother-daughter station ..................................................................................................... 11
5.4 Dispenser......................................................................................................................... 11
5.5 Control systems ................................................................................................................ 12
5.6 Dryer............................................................................................................................... 12
5.7 Gas cooling system ........................................................................................................... 12
5.8 Filtration........................................................................................................................... 12
6 General principles of design and installation ....................................................................................... 12
6.1 General construction.......................................................................................................... 12
6.2 Gas composition ............................................................................................................... 16
6.3 Safety devices .................................................................................................................. 17
6.4 Delivery pressure to the vehicles......................................................................................... 17
6.5 Venting ............................................................................................................................ 18
6.6 Control system.................................................................................................................. 18
7 Location and layout of equipment ........................................................................................................ 19
7.1 General provisions ............................................................................................................ 19
7.2 Hazardous areas............................................................................................................... 19
7.3 Storage Facility (including ancillary equipment) ..................................................................... 20
7.4 Compressors (including ancillary equipment) ........................................................................ 20
7.5 Dispenser......................................................................................................................... 21
7.6 Enclosures ....................................................................................................................... 21
7.7 Canopies.......................................................................................................................... 22
7.8 Restrictions and safety distances ........................................................................................ 22
8 Gas supply, metering and composition ................................................................................................ 22
-
7/30/2019 Cng Fuelling Stations for Vehicles
5/72
Draft SI 6236 (2012)
b
8.1 General Provisions ............................................................................................................ 22
9 Gas Compressors (including ancillaries) ............................................................................................. 23
9.1 General Provisions ............................................................................................................ 23
9.2 Gas recovery .................................................................................................................... 249.3 Condensate drainage and disposal...................................................................................... 24
9.4 Stage safety devices.......................................................................................................... 25
9.5 Delivery line non-return valve.............................................................................................. 25
9.6 Suction line components .................................................................................................... 25
9.7 Instrumentation ................................................................................................................. 25
9.8 Markings .......................................................................................................................... 26
9.9 Instructions....................................................................................................................... 27
10 Storage facility (including ancillaries) ................................................................................................... 27
10.1 Storage pressure vessels ................................................................................................... 27
10.2 Pressure relief devices....................................................................................................... 27
10.3 Emergency isolation valve.................................................................................................. 28
10.4 Pressure gauge ................................................................................................................ 28
10.5 Control Systems................................................................................................................ 28
10.6 Storage volume................................................................................................................. 28
11 Station pipework and ancillary devices ................................................................................................ 28
11.1 Station pipework ............................................................................................................... 28
11.2 General provisions ............................................................................................................ 29
11.3 Inlet supply pipework ......................................................................................................... 29
11.4 Outlet pipework................................................................................................................. 30
11.5 Flexible connections .......................................................................................................... 32
11.6 Pressure gauges ............................................................................................................... 32
11.7 Pressure testing ................................................................................................................ 32
11.8 Gas detection system ........................................................................................................ 32
12 Emergency shutdown procedures ........................................................................................................ 32
13 Dispenser............................................................................................................................................... 33
13.1 Dispensing unit ................................................................................................................. 33
13.2 Filling hose ....................................................................................................................... 34
13.3 Filling nozzle..................................................................................................................... 35
-
7/30/2019 Cng Fuelling Stations for Vehicles
6/72
Draft SI 6236 (2012)
c
13.4 Captive vent systems......................................................................................................... 35
14 Electrical equipment and wiring ............................................................................................................ 35
14.1 General............................................................................................................................ 35
14.2 Earthing protection ............................................................................................................ 3514.3 Lightning protection ........................................................................................................... 35
15 Testing, purging and commissioning .................................................................................................... 35
16 Marking, operating notices and instructions ........................................................................................ 36
16.1 General............................................................................................................................ 36
16.2 Marking............................................................................................................................ 36
16.3 Dispenser signs ................................................................................................................ 37
16.5 Instructions....................................................................................................................... 37
-
7/30/2019 Cng Fuelling Stations for Vehicles
7/72
-
7/30/2019 Cng Fuelling Stations for Vehicles
8/72
Draft SI 6236 (2012)
1
Foreword
The intent of this Standard is to provide requirements for safety, design, construction, testing,
commissioning, general maintenance and operation of compressed natural gas (CNG) fuelling
stations and facili t ies which take a natural gas supply from the supply network or from mobile
storage and deliver i t as fuel for the propulsion of a vehicle.
I t is addressed to both manufacturers and installers, for whom this document provides the basic
pr inciples for the design and instal la t ion of fa ci l i t ies and par ts thereof, and to operators, fo r
whom the minimum requirements for safe operation are given. I t also serves as a basis for the
inspection of natural fuelling gas stations. Additional requirements may be defined by the
authority having jurisdiction (AHJ).
I t is necessary to ensure, through the use of appropriate components and materials that CNG
fuelling stations and their components, when correctly constructed, operated and maintained are
permanent ly sa fe and op erat ional . Pr event ive measures shal l be taken to ensure pr ot ect i on
against f ire and explosion.
I t is now widely accepted that the majority of accidents in industry generally are in some
measure attr ibutable to human as well as technical factors in the sense that someone's actions
initiated or contr ibuted to the accidents or someone could have acted better to avert them.
It is therefore necessary to give proper consideration to the management of these human factors
and the control of r isk. This document includes provisions that are relevant for f i l l ing mobile
storage trailers supplying CNG to daughter fuelling stations.
The complete requirements framework will be defined by the relevant authorities and within a
future relevant standard.
-
7/30/2019 Cng Fuelling Stations for Vehicles
9/72
Draft SI 6236 (2012)
2
Introduction
This standard provides requirements for the design, construction, installation, testing,
commissioning, maintenance and operation of CNG vehicle fuelling stations.
The document makes use of the terms "should" and "shall" when prescribing particular procedures.
(a) The term "shall" prescribes a procedure which, i t is intended, will be complied with in full
and without deviation.
(b) The term "should" prescribes a procedure which, i t is intended, will be complied with
unless, af ter pr ior consideration, deviation is considered to be acceptable.
1 Scope
1.1 This standard covers the design, construction, installation , testing, commissioning and
operation and maintenance of CNG vehicle fuelling stations operating with Maximum
Operational Pressure (MOP) of 260 bar from the CNG fuelling stat ion inlet isolat ion valve
to the f il l ing nozzle.
1.2 I t applies to fuelling stations supplied with Natural Gas as defined in SI 6119.
1.3 Liquefied Natural Gas (LNG) fuelling stations are not covered by the scope of this
standard.
1.4 LNG to CNG regassif ication module is not covered by th e scope of this standard.
1.5 Vehicle Refuelling Appliances (VRA) are not covered by this standard.
1.6 The scope of the standard includes fuelling stations of the following types (as shown in
Annex J) :
On site f i l l of vehicles
Fast f i l l of vehicles
Private access
Public access (self-service or assisted)
Metered dispenser
No n metered dispenser
Mother-daughter fuelling stations
-
7/30/2019 Cng Fuelling Stations for Vehicles
10/72
Draft SI 6236 (2012)
3
The Standard also includes general cr iter ia concerning the following aspects:
a) Pressure adjustment due to temperature during refuelling;
b) Safety during f il l ing;
c) Filling hose;
d) Storage;
e) Pressure control devices;
f) Distances between components;
g) Multifuel dispensing stations;
h) Piping;
i ) Installation;
j) Final inspection and testing.
k) External safety distances
1.7 The CNG fuelling facili ty may be integrated with new or existing fuelling facili t ies of
other fuels.
1.8 This Standard applies to private and commercial stations having fast and/or slow fuelling
dispensers. I f fuelling stations are intended to be used by the general public, due regard
needs to be taken to any additional public safety, security and trading issues.
1.9 Guidance on the operation and maintenance of fuelling stations is given in Annex J.
2 Normative References
Standards and documents referenced in this Standard (for undated Standards and
documents, the latest edition applies) :
.Israeli Standards
SI 413 - Design provisions for earthquake resistance of structures
SI 4295 - Pressure vessels
SI 5512 (2004) - Automotive liquefied petroleum gas (LPG) refuelling facili t ies
SI 5664 (all parts) - Natural gas systems
-
7/30/2019 Cng Fuelling Stations for Vehicles
11/72
Draft SI 6236 (2012)
4
SI 6119 ` - Automotive natural gas
SI 1173 Part 1 - Lightning protection systems for buildings and installations:
External protection system
SI 60079 Part 10.01 - Explosive atm ospheres: Classif ication of areas Explosive g asatmospheres
International Standards
ISO 14469-1 - Road vehicles - Compressed natural gas refuelling connector - Part
1: 200 bar
ISO 14469-2 - Road vehicles - Compressed natural gas refuelling connector - Part
2: 200 bar size 2
ISO 14469-3 - Road vehicles - Compressed natural gas refuelling connector - Part
3: 250 bar
ISO 15501-1 - Road vehicles Compressed natural gas (CNG) fuel systems Part
1: Safety requirements
ISO 15501-2 - Road vehicles Compressed natural gas (CNG) fuel systems Part
2: Test methods
ISO 15609-1 - Specif ication and approval of welding procedures for metallic
materials Welding procedure specif ication - Part 1: Arc welding
ISO 15609-2 - Specif ication and qualif ication of welding procedures for metallic
materials Welding procedure specif ication - Part 2: Gas welding
IEC 60079-29 - Gas detectors Performance requirements of detectors for f lammable
gases
European Standards
EN 287-1 - Qualification test of welders - Fusion welding - Part 1: Steels
EN 473 - Non-destructive testing - Qualification and certification of NDT personnel General principles
EN 1012-1 - Compressors and vacuum pumps; Safety requirements Part 1: Compressors
EN 10204 - Metallic products Types of inspection documents
EN 15001-1 - Gas Supply systems Gas installation pipework Part 1 design requirements
EN 13445-1 - Unfired pressure vessels - Part 1: General
EN 13445-2 - Unfired pressure vessels - Part 2: Materials
-
7/30/2019 Cng Fuelling Stations for Vehicles
12/72
Draft SI 6236 (2012)
5
EN 13480-1 - Metallic industrial piping - Part 1: General
EN 13480-2 - Metallic industrial piping - Part 2: Materials
EN 13480-3 - Metallic industrial piping - Part 3: Design and calculation
EN 13480-4 - Metallic industrial piping - Part 4: Fabrication and installation
EN 13480-5 - Metallic industrial piping - Part 5: Inspection and testing
EN 13480-6 - Metallic industrial piping - Part 6: Additional requirements for buried piping
National Standards
IGE/UP/5 part 3 Natural gas vehicles Fill ing station operations
IGEM/SR/25 ed.2 - Hazardous area classif ication of Natural Gas installations
ASME B31.3 Process piping
ASME VIII-1 Boiler and Pressure Vessel Code - Rules for Construction of Pressure
Vessels
NGV1 - Com pressed Natural Gas Vehicle (NGV) Fuel ing Connect ion Devi ces
Israeli legislation:
Tama 18 Rev. 4 (2006) National Outline Plan for Fuel Stations
Electr icity regulations 2004
Other legislation:
Directive 97/23/EC of the European Parliament and of the Council of 29 May 1997 on the
approximation of the laws of the Member States concerning pressure equipment
Directive 98/37/EEC The Approximation of the Laws of the Member States Relating to
Machinery
3 Definitions
For the purpose of this Standard, the fol lowing def init ions apply:
3.1 Enclosed space
a structure that cannot be def ined as an open bui lding
3.2 Burst pressure (pb)the pressure which causes fai lure and consequential f lu id loss through the component
envelope
-
7/30/2019 Cng Fuelling Stations for Vehicles
13/72
Draft SI 6236 (2012)
6
3.3 Break-away device
a device which, when act ivated, stops gas f low from the dispenser (for example i f the
vehic le moves away) whi le st i l l connected to the refuel l ing hose
3.4 Canopy
a roof, for example a shelter, a hood etc. , which affords a degree of weather protection
3.5 Cascade dispensing sequence
a means of al lowing eff ic ient use of the gas storage faci l i ty by dividing i t into banks
operating at dif ferent pressure levels
3.6 Competent person
a person having the abi l i ty, appropriate training, knowledge and experience, to supervise
or carry out the work being undertaken in a safe and proper m anner
3.7 Compression unit
a unit that compresses the natural gas consist ing of one or more compressors, including
al l p iping and equipment
3.8 Compressor
a machine which increases the pressure of gas from a low to a higher level
3.9 Cyl inder
any vessel used for the storage of compressed natural gas
3.10 Blow down vessel
a vessel which receives compressed gas from the high pressure section of the instal lat ion
and conducts i t to the input of the compression system and also serves to col lect the
el iminated l iquids
3.11 Dispenser
the equipment through which the compressed natural gas is suppl ied to the vehic le
3.12 Dryer
a system which decreases the water content of the natural gas
3.13 Enclosure
a designated structure, not a bui lding, such as a housing, a container etc. , which encloses
components of the stat ion
-
7/30/2019 Cng Fuelling Stations for Vehicles
14/72
Draft SI 6236 (2012)
7
3.14 Explosive gas atmosphere
a mixture with air , of a f lammable material in the form of gas or vapour in which, after
ignit ion, combustion spreads throughout the unconsumed mixture
3.15 Fast f i l l
a f i l l ing operation which is comparable in duration to that of l iquid fuel
3.16 CNG fi l l ing/fuell ing area
a location at which CNG is dispensed into a vehic le or to a mobi le CNG storage.
3.17 Fire wall
a wal l , screen or separating part it ion erected in the open air to reduce the effects from
radiated heat and to e nsure an adequate dispersion distance for CNG leaking from any
vessel
3.18 Gas condit ioning equipment
equipment to f i l ter and/or remove unwanted constituents (moisture, debris, l iquid and
vapours) from the gas either prior to or after compression
3.19 Hazardous area
an area in which an explosive gas atmosphere (f lammable gas-air mixture) is present, or
may be expected to be present, in quantit ies such as to require special precautions forthe construction, instal lat ion and use of el ectr ical apparatus and other sources of
ignit ion
3.20 Liquid separator
a device which causes any l iquids within the gas to drop out of suspension for col lect ion
and can be located after compression of the natural gas
3.21 Lower explosive l imit (LEL)
the concentration of f lammable gas or vapour in air below which the gas atmosphere is
not explosive. (For natural gas containing only methane the LEL is 4.5 % by volume. For
example 10 % LEL means 0.45 % gas in air . )
3.22 Maximum operational pressure (MOP)
the maximum pressure at which the system can be operated continuously under normal
condit ions.
Note :
Normal condit ions are no fau lt in any dev ice or stream.
-
7/30/2019 Cng Fuelling Stations for Vehicles
15/72
Draft SI 6236 (2012)
8
3.23 Overpressure
the pressure above the maximum operational pressure which shal l be prevented by safety
devices
3.24 Delivery pressure
the pressure at which the gas is del ivered to the vehic le
3.25 Nominal del ivery pressure
the pressure at which f i l l ing automatical ly stops
3.26 Maximum delivery pressure
the maximum pressure acceptable by the vehic le to be f i l led
3.27 Mobile CNG storage vessel
a pressure vessel (mult i -cyl inder or a tank) used for the transportation of CNG to other
fuel l ing stat ions.
3.28 Mother-daughter
a stat ion not connected to the pipel ine (daughter) where CNG is suppl ied by a mobi le
CNG storage transported from a stat ion connected to the pipel ine (mother).
3.29 Natural gas
a mixture of gases, hydrocarbons or others, mainly methane (CH4 ) , in the gaseous state at
a temperature of 15 C and at atmospheric pressure (1.013 bar).
3.30 Normal operation
a situation where the equipment is operating within i ts design parameters
3.31 Safe area
an area in which an explosive gas is not expected to be pre sent in quantit ies such as to
require special precautions for the construction, instal lat ion and use of apparatus
3.32 Open building
a construction, in which the same venti lat ion condit ions are present as in the open air
and no obstruction for natural air c irculat ion is present
3.33 On site fi l l ing
f i l l ing where many vehic les are connected at the same t ime for several hours
-
7/30/2019 Cng Fuelling Stations for Vehicles
16/72
Draft SI 6236 (2012)
9
3.34 Primary grade of release
release of gas which is l ikely to occur under normal operation
3.35 Recovery vessel
a vessel that r ecovers gas from the compressor and its anci l lar ies and which may also
serve to damp out pressure pulsations in the compressor inlet
3.36 Safety distance
Theseparation distance between the fuel l ing stat ion, i ts components and structures and
other instal lat ions and structures in the vi c inity for protecting people and reducing the
degree of danger in the case of an incident
3.37 Secondary grade release
the release of gas which is unl ikely to occur in normal operation and wi l l have only a
l imited duration
3.38 Slow fill
a f i l l ing operation which takes, typical ly, several hours
3.39 Station owner/operator
the person who owns, or is responsible for the operation of the fuel l ing stat ion
3.40 Storage
any number of suitable compressed natural gas storage containers designed for the
purpose of containing and subsequently releasing compressed natural gas
3.41 Test pressure (TP)
the pressure to which the instal lat ion or part of instal lat ion, is tested. Dif ferent levels
may be required for storage pressure vessels and other components
3.42 Venti lat ion
either natural movement of air and its replacement with fresh air due to the effects of
wind, temperature gradients, or mechanical movement by art i f ic ial means (for example
fans or extractors)
3.43 Vehicle refuell ing appliance (VRA)
a self -contained system that compresses natural gas and dispenses the gas to a s ingle
vehic le fuel system via s low f i l l .
-
7/30/2019 Cng Fuelling Stations for Vehicles
17/72
Draft SI 6236 (2012)
10
3.44 Hazardous area classification (according to SI 60079-10.01)
3.44.1 Zone 0
an area in which an explosive gas atmosphere is present continuously or for long
periods or frequently
3.44.2 Zone 1
an area in which an explosive gas atmosphere is l ikely to occur in normal operation
occasional ly
3.44.3 Zone 2
an area in which an explosive gas atmosphere is not l ikel y to occur in normal operation
but, i f i t does occur, i t wi l l persist for a short period only
3.454 CNG fuell ing station inlet isolation valve
connection point to the suppl ier as def ined by Israel i law
3.465 Inlet supply pipework
the pipework section upstream the compressor.
3.476 Outlet pipework
the pipework section downstream the compressor.
4. Abbreviations
pb - burst pressure
AHJ - Authority having jurisdiction
MOP - Maximum operating pressure
NHA - Non-hazardous area
TP -Test pressure
STP - Strength test pressure
TTP - T ightness test pressure
LEL - Lower explosive l imit
CNG - Compressed natural gas
NGV - Natural gas vehic le
PRV - -Pressure rel ief valve
VRA - Vehic le refuel l ing appl iance
-
7/30/2019 Cng Fuelling Stations for Vehicles
18/72
Draft SI 6236 (2012)
11
5 General provisions
A comprehensive scheme of possible components is shown as an e xample in the diagram in
Annex I . For al l components of a CNG fuel l ing stat ion, the manufacturer shal l provide
proof of their conformity to specif icat ion.
5.1 Gas compressor
In general , gas compressors for Natural Gas fuel l ing stat ions produce high pressure l i f ts.
Compressors may supply to bulk storage and/or to a direct fuel l ing faci l i ty. A typical
compressor, for example would be a mult i -stage machine which may be direct ly or
indirect ly driven by an electr ic motor i n stat ionary faci l i t ies. The compressor shal l be in
compliance with the essential requirements of European Directive 98/37/EEC on
machinery and with EN 1012-1
5.2 Gas storage
A certain volume of gas may be stored to faci l i tate fast f i l l ing of vehic les. For example,
storage is provided in banks of mult iple vessels to speed up fuel l ing, to optimise the
station design and to l imit the number of start/stop cycles of the g as compressor. Often,
cyl inders are manifolded together to form dif fering pressure groups to enable a cascade
dispensing sequence.
5.3 Mother-daughter station
All components of the stat ionary parts of this type of stat ion have to comply with this
standard. The mobi le storage (with or without on-board compressor) shal l comply with
transportation regulat ions. In al l other situations this standard appl ies.
5.4 Dispenser
5.4.1 Components
A dispenser comprises for example:
- a dispensing and optional metering unit;
- a f i l l ing hose;
- a f i l l ing nozzle.
Gas for dispensing is drawn either direct ly from a compressor or via on-site storage,
and then passed into the vehic le CNG cyl inder.
5.4.2 Fuell ing methods
Vehicle fuel l ing can be undertaken in the fol lowing ways:
-
7/30/2019 Cng Fuelling Stations for Vehicles
19/72
Draft SI 6236 (2012)
12
a) Fast-f i l l ;
b) On site f i l l/s low f i l l ;
c) With temperature compensation.
If s low-f i l l faci l i t ies are unattended during the fuel l ing operation, then the instal lat ion
of extra safety and security systems is necessary.
5.4.3 Operation
The dispenser can be operated in several forms, for example:
a) Manual ly or automatical ly operated;
b) Metered or unmetered;
c) A f i l l -post, which is used on slow fuel l ing stat ions;
d) Assisted or self -service
5.5 Control systems
A control system operates the compressor and/or any storage faci l i ty in conjunction with
the demands of the dispenser.
5.6 Dryer
A drying system may be required to control the water content of the gas to comply withrelevant standards. (See SI 6119 for CNG qual ity). If the drying system used reduces the
odorant present in the gas, odorisat ion equipment shal l be added to re-odorise the gas to
the required level .
5.7 Gas cooling system
A system may be required to control the del ivered gas temperature.
5.8 Filtration
I f f i l trat ion is required. i t shal l be sized for the maximum gas f low and have a suitable
col lect ion device and a means of r emoval/exchange. Dif ferential pressure monitoring
should be used to check performance.
6 General principles of design and installation
6.1 General construction
All equipment, components, pipework and f i tt ings shal l be of a type and manufacture and
be assembled in such manner suitable for their intended use, for the ful l range of
pressures, type of gas, temperatures, weather condit ions and loadings which may occur
-
7/30/2019 Cng Fuelling Stations for Vehicles
20/72
Draft SI 6236 (2012)
13
under normal and fault condit ions. These shal l be supported by appropriate cert i f icat ion
(such as in EN 10204). These shal l be instal led and used in accordance with the
manufacturer's instructions.
The design of the stat ion shal l ensure that al l the individual elements are compatible and
can be integrated.
Consideration shal l be given to pressurisat ion and depressurisat ion of components e.g.
for removal for maintenance purposes, draining condensate, by the provision of valves,
gauges and vent connections to ensure that sect ions are depressurised before service
interventions. The design process shal l i nvolve appropriate r isk assessments (such as
HAZID, HAZOP, FMEA etc. ) to determine the adequacy of the proposed systems and
procedures to mit igate harm or damage to acceptable levels.
6.1.1 Materials
All material used for the construction of the stat ion shal l conform to the required
specif icat ions. In part icular, documentation provided by the material manufacturer
aff irming compliance with the specif icat ion must be obtained for al l materials used
for the production of pressure carrying components. For the main pre ssure-bearing
parts, this shal l take the form of a cert i f icate of specif ic product control . Where a
material manufacturer has an appropriate qual ity assurance system, cert i f icates
issued by the manufacturer should identify conformity with the relevant
requirements.
Materials used for the construction of pressurized parts shal l :
a. have suitable propert ies for al l operating condit ions which are reasonably
foreseeable and for al l test condit ions. In part icular, they should be suff ic iently
ducti le and tough. Moreover, due care should be exercised, in part icular, in
select ing materials in order to prevent britt le-type fracture, where necessary;
b. be chemical ly resistant to del ive red qual ity natural gas in accordance with SI 6119,
and, i f appl icable, to rege nerative produced gases;
c. not be signif icantly affected by ageing;
d. be resistant to corr osion or, alternatively, protected against corrosion by suitable
means;
-
7/30/2019 Cng Fuelling Stations for Vehicles
21/72
Draft SI 6236 (2012)
14
e. be suitable for the intended pressures, pressure cycl ing and temperatures and the
variat ions thereof;
f . be selected in order to avoid signif icant undesirable effects when the various
materials are put together.
6.1.2 CNG fuel l ing stat ions under the scope of this standard may be subject to the global
conformity assessment procedure which is appl icable for assembled products from a
variety of sources under the r esponsibi l i ty of the manufacturer.
6.1.3 Requirements for the various elements of the assembly
These shal l not only be appropriate to their normal functioning but also take into
account the effect of extraneous forces such as the effects of changes in pressure and
temperature, and forces and vibrations set up during manufacturing and assembly.
This impl ies proof of adequate strength either by calculat ion or by experimental
design. Al l the elements of assembly shal l be protected against corrosion by means of
suitable systems, such as painting, and/or cathodic protection, taking into account
environmental condit ions.
6.1.4 Optional components
Optional components (e.g. dryers, odorisers, f i l ters and chi l lers) shal l not impair the
operabi l i ty and safety of the fuel l ing stat ion.
6.1.5 Permanent joining of components
Permanent joints and adjacent zones shal l be free of any surface or internal defects
detrimental to the safety of the system. The propert ies of permanent joints must meet
the minimum propert ies specif ied for the materials to be joined unless other relevant
property values are specif ical ly taken into account in the design calculat ions. The
number of joints should be kept to a minimum.
Any joining of components shal l be performed by a competent person. I n part icular,
welded connections shal l be produced by a suitably qual i f ied welder in accordance
with EN 287-1.
The welding shal l be carr ied out in accordance with ISO 15609-1 or ISO 15609-2 taking
into account any necessary heat treatment and traceabi l i ty of materials.
Al l weldedpermanent joints shal l be subject to non-destructive tests carr ie d out by
suitably qual i f ied personnel , e.g. in compliance with EN 287-1 and EN 473.
-
7/30/2019 Cng Fuelling Stations for Vehicles
22/72
Draft SI 6236 (2012)
15
6.1.6 Working area
A suff ic ient working area for checking, maintenance and service shal l be avai lable.
Components such as cyl inder banks may have to be removed at intervals for
reval idation. etc.
6.1.7 Noise attenuation
Control of noise during operation and maintenance act iv it ies shal l comply with local
legislat ion and site requirements. This i ncludes noise generated by compressors and
venti lat ion systems and from pressure rel iefs and venting operations.
6.1.8 Coll is ion protection
The fuel l ing stat ion components shal l be adequately protected ag ainst col l is ion by
vehic les. Special consideration shal l be given to col l is ion protection of the storage and
dispenser. Addit ional protection shal l be provided in the area surrounding a dispenser
serving mobi le storage (mother-daughter) vehic les, or a stat ion suppl ied by a mobi le
storage.
6.1.9 Traffic management
Consideration should be given to the f l ow of vehic les on the stat ion premises. Gr eater
levels of access may be required where the stat ion is suppl ied by a mobi le storage.
Mobi le storage vehic les not undertaking supply shal l not be permitted to park in the
station premises.
6.1.10 Foundation
The compressed natural gas fuel l ing stat ion shal l be mounted on adequate
foundations. The foundation design shal l comply with the Israel i standard for
earthquakes (SI 413).
6.1.11 Unauthorized access
There shal l be adequate means provided such that safety of operation cannot be
affected by unauthorized interference. Equipment shal l be suitably protected to deter
unauthorised access and to minimise the effects of interference, damage and
vandal ism. Addit ional precautions may be necessary to protect mobi le storage units
during supply operations.
-
7/30/2019 Cng Fuelling Stations for Vehicles
23/72
Draft SI 6236 (2012)
16
6.1.12 Location of components
Equipment shal l be located preferably in open air or dedicated enclosures. In al l other
cases, due consideration shal l be given to safety and venti lat ion requirements.
Electr ical components shal l be suitably rated for their location.
6.1.13 Building regulations
Consideration shal l be given to local bui lding regulat ions and permits.
Al l on-site constructions shal l comply with the I srael i standard for earthquakes (SI 413).
6.1.14 Fire
Levels of f i re protection required by the Israel i f i re authority shal l be implemented.
6.1.15 Routine isolation
A manual isolat ion valve shal l be f i tted to:
the compressor inlet pipework;
the inlet/outlet of any group/bank of storage pressure vessels;
the inlet gas supply of any dispenser;
6.2 Gas composition
6.2.1 General
Compressed natural gas dispensed by the fuel l ing stat ion shal l be according to SI 6119.
6.2.2 Gas supplied to the fuell ing station
The gas supply and metering equipment for the stat ion shal l be suitable for the
fuel l ing stat ions requirements.
6.2.3 Gas supplied to the dispenser
Gas suppl ied to the dispenser shal l have a part iculate matter level which wi l l not
cause malfunction of the dispensing equipment and shal l comply with dispenser
manufacturer requirements.
-
7/30/2019 Cng Fuelling Stations for Vehicles
24/72
Draft SI 6236 (2012)
17
6.2.4 Gas Composit ion during maintenance
Any maintenance or servic ing antic ipated during operation of the fuel l ing stat ion shal l
not affect adversely the composit ion of gas suppl ied from the stat ion.
6.3 Safety devices
6.3.1 General
Fuel l ing stat ions shal l be equipped with safety devices that prevent overpressure in
any part of the fuel l i ng stat ion and its pipework, and the uncontrol led release of
pressurized gas.
Safety devices shal l be ful l y independent of other functions, unless their safety
function cannot be affected by such other functions. They shal l comply with
appropriate design principles in order to obtain suitable and rel iable protection.
6.3.2 Automatical ly operated safety device
The compressed natural gas dispensing system shal l be equipped with an
automatical ly operated safety device, which wi l l work in such a way that the del ivery
pressure to the vehic le cannot exceed the maximum operating pressure.
6.3.3 Safety isolation devices
Safety isolat ion devices shal l include at least:
an automatic emergency gas isolat ion valve which i solates:
- the stat ion;
- storage;
- dispenser(s);
(a) suitably located emergency shutdown button(s).
The type of automatic valves f i tted shal l be suitable for the required operation and
location.
6.4 Delivery pressure to the vehicles
The maximum del ivery pressure of the compressed natural gas to the vehic le shal l not
exceed 260 bar for fuel l ing stat ions, regardless of temperature. The fuel l ing stat ion has
to control the f i l l ing of the vehic le in such a manner as to obtain an on-board gas mass
not exceeding the mass corresponding to storage at 200 bars and 15 C.
-
7/30/2019 Cng Fuelling Stations for Vehicles
25/72
Draft SI 6236 (2012)
18
6.5 Venting
Where rel ief valve vents are manifolded together, operation of any rel ief valve shal l not
be impeded or obstructed.
Venting shal l not be possible into enclosures.
Where more than one piece of s imi lar equipment (e.g. compressors, dispensers or storage
banks) is instal led, manifolded vents from each piece of s imi lar equipment shal l not be
connected together.
Rel ief vent l ines shal l not be impeded or obstructed. Where isolat ion valves are required
for test ing/cal ibration purposes, they shal l be locked in the open posit ion.
A hazardous area c lassi f icat ion assessment of the vent end points shal l be undertaken
and appl ied.
Note :
The analys is wi l l be d i f ferent for d i f fer i ng designs of vent.
Vent manufacturers should be able to provide the re quired information.
Permanent or temporary ignit ion sources shal l not be permitted within the vent end point
calculated radius.
Safety rel ief valves shal l vent to the atmosphere and the vent pipe end point shal l :
a) be facing upward and be unimpeded;
b) be located at a safe area outdoors at a height of at least 3 m above the ground, and at
least 1 m higher than any bui lding roof level within the calculated radius per c lause
7.2 of this standard.
c) be designed to take account of the adverse effects of rain, condensation, foreign
bodies and rust.
6.6 Control system
The control system for the fuel l ing faci l i ty shal l ensure the safe del ivery of CNG to the
dispensing units. It shal l not override or adversely affect any of the essential safety
devices or emergency shutdown systems.
Al l control system components and wir ing shal l comply with the hazardous area
classi f icat ion requirements.
-
7/30/2019 Cng Fuelling Stations for Vehicles
26/72
Draft SI 6236 (2012)
19
7 Location and layout of equipment
7.1 General provisions
Site location shal l comply with separation distances as outl ined i n TAMA 18, c lause
15.1/A, sub-sections 1 and 2.
S ite location and layout shal l be planned careful ly as most of the site components have
location restr ict ions and minimum safety distances and may be affected by hazardous
area requirements. Annex B g ives guidance on the minimum safety distances to be
appl ied. These restr ict ions may only be reduced where special measures are taken to
remove or reduce the effect of the hazard.
If the CNG fuel l ing faci l i ty is integrated with new or exist ing fuel l ing faci l i t ies of other
fuels, the requirements of this standard and those of the other fuel l ing faci l i t ies shal l be
ful ly implemented.
7.1.1 Location
Location should be preferably in the open air and in a wel l venti lated location, but
under certain condit ions in a separate f i t for purpose enclosure. Any security fence or
f ire wal l shal l not interfere with the venti lat ion aspects of the open area or enclosure.
7.1.2 Fire fighting
Consideration shal l be given to accessibi l i ty by f i re f ighters and their equipment.
7.2 Hazardous areas
7.2.1 A hazardous area c lassi f icat ion analysis of the fuel l ing stat ion and its components
shal l be undertaken and implemented for the location of e lectr ical equipment and
other sources of ignit ion. Special attention must be given to exist ing equipment and
structures, such as high voltage equipment and overhead cables. Precautions shal l be
taken for any hazardous areas generated by other equipment exist ing on the site (oradjacent to i t) . Vent terminations shal l also be c lassi f ied (see c lause 6.5).
The c lassi f icat ion shal l be in accordance with Israel i Standard SI 60079 Part 10.01.
Further guidance is given in Annex A.
7.2.2 Hazardous areas may have to be provisional ly determined at an early stage in a
project to al low electr ical equipment to be specif ied and other potential sources of
ignit ion to be located. However, a hazardous area c lassi f icat ion drawing shal l be
-
7/30/2019 Cng Fuelling Stations for Vehicles
27/72
Draft SI 6236 (2012)
20
produced prior to instal lat ion of the fuel l ing stat ion and shal l be based on the
requirements in Israel i Standard SI 60079 Part 10.01.
Further information is given in IGEM/SR/25 ed.2.
7.2.3 Both new and exist ing instal lat ions shal l comply with SI 60079 Part 10.01 when
affected by new hazardous areas.
7.2.4 The hazardous area shal l not e xceed the boundary of the property.
7.2.5 All identi f ied hazardous areas shal l be maintained and revi ewed at regular intervals.
7.2.6 All of the CNG fuel l ing stat ion components, excluding the dispensers, shal l be
restr icted from unauthorised access.
7.3 Storage Facility (including ancillary equipment)
7.3.1 Instal lat ion shal l be in a wel l venti lated location, ideal ly in the open air . However,
where this may have unacceptable aspects, for example, due to safety, security, noise
levels, weather protection etc. , consideration may be given to the use of a f i t for
purpose enclosure, with a suitably designed venti lat ion system. I nstal lat ion in
bui ldings shal l not be permitted.
In exceptional cases, i f supported by appropriate r isk assessments, consideration may
be given to the use of a suitably designed and protected below ground storage faci l i ty.
More information is given in Annex K.
In addit ion, the base of the faci l i ty shal l be designed to prevent the col lect ion of
l iquids, for example water, l iquid fuels etc. , beneath the storage pressure vessels.
7.3.2 Adequate access, including overhead i f appropriate, should be given to permit
removal and exchange of individual banks of storage vessels, dependent upon design,
to al low reval idation. Consideration shal l be g iven to the protection of manifold
pipework during removal of vessels.
7.3.3 Mobile storage units shal l be located in open air wel l venti lated locations during
supply operations.
7.4 Compressors (including ancillary equipment)
7.4.1 Instal lat ion shal l be in a wel l venti lated location, ideal ly in the open air . However,
where this may have unacceptable aspects, for example, due to safety, security, noise
levels, weather protection etc. , consideration may be given to the use of a f i t for
-
7/30/2019 Cng Fuelling Stations for Vehicles
28/72
Draft SI 6236 (2012)
21
purpose enclosure, with a suitably designed venti lat ion system. I nstal lat ion in
bui ldings shal l not be permitted.
7.4.2 Adequate access, including overhead, i f appropriate, should be given to permit
removal and replacement of individual compressor.
7.5 Dispenser
7.5.1 Dispensers shal l be located so that vehic les have adequate space for manoeuvring into
and out of the f i l l ing location. This shal l be simi lar to normal fuel l ing stat ion design
for other fuels. Instal lat ion in bui ldings shal l not be permitted.
7.5.2 Where a slow-f i l l faci l i ty is provided, adequate security protection shal l be given to
protect against unauthorised interference, part icularly during periods of unmanned
fi l l ing operations.
7.5.3 The dispenser shal l comply with the hazardous area c lassi f icat ion applying to other
equipment in the area where the dispenser is placed.
Where a mobi le storage (mother/daughter) unit is to be f i l led, the dispenser shal l be
separated from any publ ic or private vehic le fuel l ing faci l i ty and shal l be used for
mobi le storage f i l l ing only.
7.6 Enclosures
7.6.1 General Provisions
It is preferable to instal l any compressor or storage faci l i ty in the open air . However,
where this may have unacceptable consequences, e.g. for safety, security, noise
levels, weather protection etc. , consideration may be given to the use of a f i t for
purpose enclosure, with a suitably designed venti lat ion system. Suitably designed
explosion rel iefs shal l be provided i f identi f ied by the r isk assessment.
7.6.1.1 A compressor and storage faci l i ty, including their respective anci l lar ies, may be
housed in the same enclosure. Control panels may be instal led in a separate
compartment within the same enclosure.
7.6.1.2 An enclosure used to house a compressor and/or a storage faci l i ty, including their
respective anci l lar ies, shal l not be used for any other purpose.
7.6.1.3 A venti lat ion system shal l be provided for the enclosure which:
ensures continuous di lut ion of the internal volume such that a potential gas
release wi l l not produce a concentration of 10 % LEL;
-
7/30/2019 Cng Fuelling Stations for Vehicles
29/72
Draft SI 6236 (2012)
22
ensures that there are no dead spaces where a f lammable mixture can accumulate;
provides suff ic ient venti lat ion for any equipment cool ing requirements;
uses uncontaminated air taken from a non-hazardous area, using inlets posit ioned
so that a f lammable mixture cannot be created;
Uses venti lat ion openings which are not subject to inadvertent obstruction.
Acoustic treatment shal l not reduce the effect iveness of the openings.
7.6.1.4 A mechanical venti lat ion system design shal l include controls to ensure safe shutdown
and safe maintenance of the system on and fol lowing fai lure of the venti lat ion system.
It may be appropriate to have a combination of both mechanical and natural
venti lat ion to help faci l i tate fai lure of the mechanical venti lat ion.
7.6.1.5 Enclosures shal l be secured agai nst unauthorised access. Access to the enclosure shal l
be control led by suitable procedures to e nsure the safety of persons enteri ng.
7.7 Canopies
Any canopy shal l not inhibit natural venti lat ion and shal l be designed to prevent the
accumulation of any gas release.
7.8 Restrictions and safety distances
See SI 60079 Part 10.01 and Annex B.
7.8.1 General Provisions
I f a f i re wal l is constructed, thus reducing the minimum safety distances, i t shal l be of
at least 1 hour f i re resistant construction, impermeable and of sol id masonry or
concrete. The wal l shal l be at least as high as the highest component and have a
minimum height of 2 m. The f ire wal l shal l not interfere with the venti lat ion aspects,
maintenance access or escape routes.
8 Gas supply, metering and composition
8.1 General Provisions
Consideration shal l be given to the effects of the operation of a compressor on the local
gas supply network.
The gas transportation company shal l be advised of the existence of the i nstal lat ion in
order that the antic ipated transient f low variat ions can be checked for compatibi l i ty with
the overal l gas supply/metering system for the site.
-
7/30/2019 Cng Fuelling Stations for Vehicles
30/72
Draft SI 6236 (2012)
23
Where the gas is suppl ied by a mobi le unit the compressor or storage faci l i ty on the
station shal l be compatible with supply from a mobi le storage unit .
8.1.1 Connection to the gas supply
The capacity of the gas supply network shal l be suff ic ient to cope with the gas
compressor suction requirements, and compressor operation shal l not create
problems of low f low rate, low pressure, or pulsation for the l ocal gas supply network.
The capacity of the mobi le storage unit shal l be suff ic ient to sat isfy the stat ions
storage and del ivery re quirements. The design of the connection system shal l permit
safe and secure connection and disconnection.
8.1.2 Non-return system
A non-return system shal l be f i tted i mmediately downstream of the CNG stat ion inlet
isolat ion valve.
The system should consist of , as a minimum, two devices, e.g. a non-return device and
a pressure operated slam-shut device.
8.1.3 Low inlet pressure
A safety device (e.g. a pressure switch) shal l be instal led for shutt ing down the
compressor and prevent automatic re-start i f the i nlet gas pressure to the compressor
fal ls below an acceptable level , as def ined by the manufacturer.
8.1.4 Special equipment
It may be necessary to provide gas condit ioning equipment, f i l ters and pressure
regulat ion which shal l be designed and constructed to appropriate standards. If
unodorised gas is suppl ied, odorising equipment wi l l be required, noting that any
dryers may reduce odorant levels.
The system shal l be designed such that any element can be replaced safely and easi ly.
9 Gas Compressors (including ancillaries)
9.1 General Provisions
9.1.1 Gas supplied from compressors
The gas suppl ied from the compressor(s) shal l not cause malfunction of equipment
downstream of the compressor with respect to corrosion and blockage. The
-
7/30/2019 Cng Fuelling Stations for Vehicles
31/72
Draft SI 6236 (2012)
24
compressor(s) shal l incorporate a means to minimize l iquid carryover into the storage
or dispensing system.
9.1.2 Design
The compressor(s) shal l be designed for safe operation and should be capable of
continuous ful l load duty.
9.1.3 Vibration
The compressor(s) shal l be provided with adequate means of balancing, support or
mounting to minimise the transmission of mechanical v ibration to the structure and
connected equipment. The inlet and outlet connections of the compressor(s) shal l be
designed to prevent the transmission of v ibration to pipework and equipment.
9.1.4 Pulsation
The compressor(s) shal l be provided with a suitable device which protects the outlet
system from unacceptable pressure pulsations.
9.1.5 Protection against weather
A compressor intended for outdoor instal lat ion has to be adequately protected against
weather condit ions to ensure safe and rel iable operation. Precautions shal l be taken
in order to protect the compressor and anci l lar ies from heat radiat ion ( i .e. sun
radiat ion).
9.1.6 Accessibi l ity
Components, integral parts and user controls that may require adjustment or
replacement during servic ing, operation and maintenance shal l be readi ly accessible.
9.2 Gas recovery
9.2.1 General provisions
Consideration should be given to recovery of gas released from separators using a
suitable system which is acceptable to the compressor manufacturer.
9.3 Condensate drainage and disposal
A safe and control led system shal l be used to faci l i tate l iquid removal from the point of
condensate col lect ion. In part icular, any pressure rel ieved during this act ion shal l not
endanger the operator or any other person.
-
7/30/2019 Cng Fuelling Stations for Vehicles
32/72
Draft SI 6236 (2012)
25
Condensate shal l be considered as hazardous waste and shal l be disposed in accordance
with the Israel i hazardous waste regulat ions.
9.4 Stage safety devices
9.4.1 General provisions
Each stage of compression may be equipped with a device to prevent over -pressurising
(i .e. a pressure switch). However, a safety valve shal l be provided for the f inal stage
of the compressor.
9.4.1.1 Resett ing of the control system shal l be by manual means.
9.4.2 Relief Valve
The f inal stage shal l have a ful l capacity rel ief valve which shal l vent to the
atmosphere or may vent to a recovery vessel , which i tself shal l have a rel ief valve
which vents to the atmosphere.
9.5 Delivery line non-return valve
A suitable non-return device shal l be f i tted to the compressor discharge l ine to prevent
loss of downstream pressure when the compressor is unloading and when the l iquid
separator is draining.
9.6 Suction line components
The procedures discussed in this subclause are in addit ion to those given in c lause 8.
9.6.1 General provisions
A normal ly c losed valve shal l be f i tted to isolate the gas supply to the compressor
whenever the compressor is not in operation.
9.7 Instrumentation
9.7.1 An hours run meter shal l be provided for the purpose of identifying maintenanceintervals.
9.7.2 The compressor system shal l be f i tted with shutdown devices in the event of the
fol lowing:
low gas inlet pressure;
high gas inlet pressure i f exceeding the c ompressor inlet pressure can occur;
high gas outlet pressure;
-
7/30/2019 Cng Fuelling Stations for Vehicles
33/72
Draft SI 6236 (2012)
26
high outlet temperature at the f inal stage;
and when appl icable:
low lubricant pressure/level ;
high hydraul ic oi l temperature ;
low hydraul ic oi l level ;
high temperature of cool ing f luid.
Other adverse condit ions may need to be taken into account.
9.7.3 Indicators shal l be provided to show that the electr ical supply is "on" and that the
motor is operating.
9.7.4 The compressor(s) shal l shut down safely in the event of loss of energy supply (to the
compressor drive).
9.7.5 The compressor(s) shal l shut down safely in the event that the storage PRV were to
st ick open, or the storage thermal rel ief valve is act ivated.
9.8 Markings
A compressor shal l be suitably m arked by the manufacturer according to the appl icable
requirements. It shal l bear the fol lowing markings in a durable, legible manner on a
f irmly attached plate:
identi f icat ion of compressed gas (e.g. CNG compressor).
identi f icat ion of the manufacturer and, where appropriate, identi f icat ion of his
authorized representative establ ished within the country;
the year of manufacture;
unique identif icat ion of the compressor, such as type, seri es or batch identif icat ion
and/or serial number;
essential l imits such as maximum al l owable pressures and temperature; rated power
in kW and supply voltage in V;
maximum operating pressure of the compressor.
-
7/30/2019 Cng Fuelling Stations for Vehicles
34/72
Draft SI 6236 (2012)
27
All electr ical motor and anci l lar ies shal l be marked as suitable for use in hazardous area
according to appl icable standards.
Al l operational valves of the compressor and anci l lar ies shal l be label led with
identif icat ion tags, displayed on the P&ID diagram.
The P&ID diagram shal l be placed adjacent to the compressor.
9.9 Instructions
The compressor(s) shal l be provided with comprehensive instal lat ion instructions,
diagrams, maintenance ( including purging procedure), servic ing and user instructions.
10 Storage facility (including ancillaries)
10.1 S torage pressure vessels
10.1.1 Al l CNG storage vessels shal l comply with the European Directive 97/23/EC,
EN 13445 1 and EN 13445-2 or ASME VII I-1.
Horizontal cyl inders shal l not be in direct contact with each other. Storage vessels
shal l be subjected to regular inspection and test ing at intervals as required by the
Israel i Standard SI 4295
10.1.2 Preca utions sha ll be taken in order to protect the stora ge fa cil ity from he at radiation
(i.e. sun radiation).
10.2 P ressure relief devices
10.2.1 At least one suitable non-temperature dependent safety device shal l be f i tted to
protect the storage system from over-pressurisat ion, with a discharge rate that is
adequate to ensure a control led depressurisat ion of the system.
10.2.2 A storage pressure vessel shal l not be isolated from a pressure rel i ef device.
Where several vessels are manifolded together with a s ingle suitably s ized rel ief
valve, no vessel shal l be able to be isolated from the rel ief valve.
10.2.3 A suitable device that releases the pressure at a temperature of 100 C 10C when
using steel pressure vessels should be f i tted to each manifolded group of vessels, in
order to permit control led discharge in the event of f i re.
Where pressure vessels made from materials other than steel are used,
documentation shal l be provided, proving that the safety device wi l l operate before
fai lure of the material due to high temperatures in case of f i re.
-
7/30/2019 Cng Fuelling Stations for Vehicles
35/72
Draft SI 6236 (2012)
28
10.2.4 Any pressure rel ief device shal l be of a design such that:
when activated, i t shal l be able to keep the pressure not exceeding 1 .1 t imes the
MOP;
i f adjus table, it ca n be se aled in the set position in orde r to pre vent una uthorize d
adjustment;
i t is marked with the set pressure and, where appropriate, the direct ion of f low;
i t d ischarges to a safe termination point per c lause 6.5 of this standard.
10.3 Emergency isolation valve
An automatic emergency isolat ion valve shal l be f i tted on the outlet from any storage
faci l i ty.
10.4 Pressure gauge
At least one pressure gauge shal l be f i tted to the storage faci l i ty.
The pressure gauge shal l be capable of reading a pressure level of at least 1.2 t i mes the
MOP.
10.5 Control Systems
Systems to control the pressure levels in dif ferent storage banks (e.g. cascade systems)
or buffer system shal l be f i t for purpose shal l not adversely affect the safety systems of
the storage faci l i ty
10.6 S torage volume
Mobile storage in publ ic stat ions shal l be l imited to two trai lers with maximum total
volume of 25,000 Nm (normal cubic meters).
11 Station pipework and ancillary devices
11.1 S tation pipework
Pipework and f i tt ings shal l be f i rmly and securely f ixed to prevent disconnection during
normal operation.
Where components are placed on dif ferent foundations, which could move separately,
consideration shal l begiven to using appropriate f lexible connections. In al l other
situations, the use of f lexible connectionsshal l be l imited and subjected to an
appropriate r isk assessment.
-
7/30/2019 Cng Fuelling Stations for Vehicles
36/72
Draft SI 6236 (2012)
29
11.2 General provisions
11.2.1 The number of mechanical joints shal l be kept to a minimum.
11.2.2 Pipework shal l be located in a location where i t cannot be damaged by moving
vehic les, or suitable protection shal l be provided.
11.2.3 Prior to pressure test ing, al l welds shal l be subjected to non destructive test ing. See
clause 6.1.5 of this Standard.
11.2.4 Pipework shal l be inspected on a regular basis. This shal l be def ined in the operation
and maintenance procedure as described in Annex J .
11.2.5 The design of the pipework wi l l consider stress analysis.
11.2.6 All operational valves shal l be l abel led with identif icat ion tags, which wi l l be
displayed on the P&ID diagram.
The P&ID diagram shal l be displayed for operational use.
11.3 I nlet supply pipework
The pressure of the inlet pipework wi l l depend upon the source. It may be low pressure i f
suppl ied from the distr ibution system, but could be up to 260 bar i f suppl ied from a
mobi le storage unit . The standard used shal l be suitable for the pressure level .
The inlet pipework shal l be in accordance with one of the fol lowing standards:
EN 15001-1, ASME B31.3. EN 13480-1, EN 13480-2, EN 13480-3, EN 13480-4, EN 13480-5
and EN 13480-6 or the relevant part of S I 5664, depending on the NG supply pressure.
The inlet pipework can be above or below ground (may be buried)
Al l in let pipework shal l be constructed of appropriate corrosion protected or stainless
steel pipe.
For mobi le supply, the design and operation of the connection system shal l permit safe
and secure connection and disconnection. The connection point shal l be securely sealed
when not connected to a supply source.
11.3.1 Above ground inlet pipework
11.3.1.1 The above ground pipework section shal l be r estr icted from unauthorised access.
11.3. 2 Buried inlet pipework
11.3.2.1 All buried pipework joints shal l be welded.
-
7/30/2019 Cng Fuelling Stations for Vehicles
37/72
Draft SI 6236 (2012)
30
11.3.2.2 Buried pipework shal l be inspected for leakage on a regular basis.
11.3.2.3 Carbon steel pipework shal l be suitably protected by an anti -corrosion system.
11.3.2.4 Where the piping is cathodical ly protected or other considerations cal l for i t ,
insulated connections shal l be f i tted to electr ical ly isolate fuel l ing devices from gas
pipework.
11.3.2.5 Insulated connections instal led above ground in hazardous areas shal l be adequately
separated to avoid sparking.
11.3.2.6 When instal l ing insulated connections outside the covered area of the fuel l ing
station, the section of underground piping, including the insulat ion joint(s), shal l be
external ly wrapped.
11.3.2.7 Underground piping shal l be marked by means of laying a warning tape above it
during construction.
11.3.3 Inlet pipework in ducts
11.3.3.1 Where pipework is instal led in below ground ducts, effect ive venti lat ion and
drainage shal l be provided. Al l p ipework joints shal l be welded and the pipework
shall be constructed of an appropriate grade of carbon steel or stainless steel.
11.3.3.2 The ducts shal l be accessible for v isual inspection of the pipework.
11.3.3.3 The construction and qual ity of the pipework shal l be the same as for above gr ound
pipework.
11.3.3.4 Pipework shal l be located in a duct or void only i f the duct or void is adequately
venti lated.
11.4 Outlet pipework
The fol lowing appl ies to pipework downstream of the compressor(s):
11.4.1 The outlet pipework shal l comply with one of the fol lowing standards, e.g. the EN
series of EN 13480-1, EN 13480-2, EN 13480-3, EN 13480-4, EN 13480-5, EN 13480-6
and ASME B31.3.
11.4.2 Above ground outlet pipework
11.4.2.1 All above ground pipework shal l be constructed of appropriate corrosion protected
or stainless steel pipe.
-
7/30/2019 Cng Fuelling Stations for Vehicles
38/72
Draft SI 6236 (2012)
31
11.4.2.2 I f possible, above g round pipework should not be used for vehic le accessed areas.
If above ground pipework is used, i t shal l be so located and protected to avoid
damage from high vehic les.
11.4.3 Below ground level outlet pipework
11.4.3.1 Pipework instal led below ground level shal l be instal led within ducts as def ined in
clause 11.4.3.3 of this standard or in below ground casing as def ined in c lause
11.4.3.4.
11.4.3.2 Pipework may be instal led i n pits containing below ground storage (see c l ause
7.3.1).
11.4.3.3 Outlet pipework in ducts
11.4.3.3.1 Ducts shal l be special ly designed for CNG use.
The ducts shal l only contain CNG pipework, drainage water l ine and compressed air
l ine, i f required.
CNG pipework shal l be separated from other pipe l ines.
11.4.3.3.2 The ducts and its covers shal l be constructed to withstand vehic le loading.
11.4.3.3.3 The ducts shal l have adequate drainage.
11.4.3.3.4 CNG pipework shal l be adequately supported and raised above the bottom of the
duct.
11.4.3.3.5 All p ipework joints in ducts shal l be welded.
11.4.3.3.6 The ducts shal l be easi ly accessible for v isual inspection of the pipework.
11.4.3.3.7 The duct shal l be adequately venti lated.
11.4.3.4 Outlet piping in casing
11.4.3.4.1 The outlet piping in casing shal l be instal led between wel l venti lated, drained pits.
When one end of the pipework i s direct ly connected to equipment ( i .e. a dispenser
or compressor) one pit (at the other end) is permitted.
11.4.3.4.2 The pits shal l be located in a safe location.
11.4.3.4.3 Pits shal l be accessible to authorised personnel only.
-
7/30/2019 Cng Fuelling Stations for Vehicles
39/72
Draft SI 6236 (2012)
32
11.4.3.4.4 Pipework periodical inspection shal l be specif ied in the operational and
maintenance procedures.
11.5 Flexible connections
Any f lexible connection shal l be suitable for the design parameters. For dispenser f i l l ing
hoses, see c lause 13.2.
11.6 Pressure gauges
11.6.1 Where appropriate, adequate monitoring devices, e.g. pressure gauges shal l be
instal led to enable adequate act ion to be taken either automatical ly or manual ly to
keep the pressure equipment within the al lowable l imits. Al l gauges shal l have a ful l
scale reading of at least 1 .2 t imes the MOP. Suitable pressure transducers may be
used.
11.6.2 All pressure gauges throughout the fuel l ing stat ion, storage faci l i t ies and dispenser
shal l have the same units.
11.7 Pressure testing
The complete instal lat ion shal l be tested for strength and t ightness using an approved
method. See also Annex E.
11.8 Gas detection system
I f a gas detection system is instal led, i t shal l comply with IEC 60079-29.
Detectors shal l be instal led in enclosures for the compressor unit and storage faci l i ty.
12 Emergency shutdown procedures
12.1 An emergency shutdown procedure shal l be provided to shut down the fuel l ing stat ion
safely and isolate the gas inlet in an emergency or in a case of a power fai lure. This shal l
be incorporated into the operational safety management system for the fuel l ing stat ion.
12.2 The procedure shal l include a compressor shutdown and isolat ion of any storage faci l i ty
outlet by the operation of automatic valves and a restart procedure after shutdown.
For example, an emerge ncy shutdown procedure could be as fol lows:
The fuel l ing stat ion power supply shal l be isolated except power for the unit monitoring
control and to the mechanical venti lat ion system;
The gas supply to the dispenser fuel l ing hose(s) shal l be isolated;
-
7/30/2019 Cng Fuelling Stations for Vehicles
40/72
Draft SI 6236 (2012)
33
The gas f low between the compressor, storage, and dispensing unit and also between
storage sections shal l be stopped. If more than one dispensing unit is connected to the
storage, the del ivery may be stopped with common valves.
The inlet valve should be automatical ly c losed during emergency shutdown.
Note:
Automatic depressur isat ion s hould be avoided during emergency shutdown.
12.3 Emergency shutdown activation devices (e.g. panic buttons) shal l be suitably located
throughout the fuel l ing stat ion. This requirement demands special attention for self -
service stat ions, in order to avoid interference and mishandl ing.
12.4 A rel iable power supply source shal l be used to operate components that are essential for
safety.
13 Dispenser
The location shal l be in a wel l venti lated location, preferably in the open air . I f not located
in the open air , the location shal l be subjected to r isk analysis.
The location shal l be in the open air for publ ic accessed fuel l ing stat ions.
13.1 Dispensing unit
13.1.1 Gas shal l only be dispensed using equipment with the fol lowing safety devices:
Break-away system. The disconnection force of the breakaway device shal l be lower
than 500 N for dispensers for personal vehic les and 850 N for high f low dispensers
for commercial vehic les, in any direct ion;
An automatic system shal l be instal led for each fuel l ing hose to shut off the gas
f low i f a pressure level of 200 bar at +15 C in the vehic le gas tank is reached or
when the fuel l ing process has ended.
13.1.2 The dispensing unit shal l be protected against vehic le col l is ion. In case of damage to
the dispenser (despite the col l is ion protector), an automatic valve or excess f low
valve shal l be act ivated c losing the supply to the dispenser at i ts in let.
13.1.3 When connected to the vehic le, the vehic le and dispensing equipment shal l be
equipotential .
-
7/30/2019 Cng Fuelling Stations for Vehicles
41/72
Draft SI 6236 (2012)
34
13.1.4 For publ ic fast-f i l l sel f -service fuel l ing stat ions, the dispensing unit shal l be equipped
with a button or handle, such that after connecting the nozzle to the vehic le, the
refuel l ing wi l l only start when this button or handle is manual ly operated.
13.1.5 Vehicles shal l be al lowed to enter the hazardous area only around the dispenser to be
fuel led.
13.1.6 Suitable cal ibrated metering systems are r equired for publ ic fuel l ing dispensers
according to the Israel i regulat ions.
13.1.7 Dispensers shal l be lockable or have other provisions for preventing their use when
the site is not manned.
13.2 Filling hose
13.2.1 The f i l l ing hose shal l be f lexible and resistant to corrosion and mechanical damage. It
shal l be adequately supported or coated to prevent kinking and abrasion.
13.2.2 The hose shal l be suitable for CNG under normal operating condit ions.
13.2.3 The length of the f i l l ing hose assembly shal l be the minimum required. It shal l ,
however, not exceed 5 metres or be less than 3 metre s.
13.2.4 The f i l l ing hose shal l be safely stowed when not in use.
13.2.5 The f i l l ing hose shal l have a burst pressure of at least 4 t imes the MOP.
The hose shal l have been subjected to a strength test of at least twice the MOP and
the test report shal l be avai lable.
13.2.6 The hose shal l be continuously marked with the MOP, date of production and the
manufacturer's name or trademark, appl icable service. The hose shal l be inspected
regularly and replaced at specif ied intervals according to the manufacturer's
instructions.
13.2.7 The hose connections shal l withstand a force in the l inear direct ion 20 % greater than
the force required to operate the break-away device (see c lause 13.1.1) and the
hose's burst pressure. The m anufacturers instructions for the breakaway device shal l
be fol lowed for instal lat ion, operation and maintenance.
-
7/30/2019 Cng Fuelling Stations for Vehicles
42/72
Draft SI 6236 (2012)
35
13.3 Filling nozzle
13.3.1 The f i l l ing nozzle shal l permit the f low of gas i f there is an adequate connection
between the nozzle and the re ceptacle device on the vehic le. The connection shal l
prevent the escape of gas when it is not ful ly engaged or becomes separated.
13.3.2 The nozzle shal l comply with the re quirements of ISO 14469 or NGV1 and shal l match
the receptacle of any vehic le complying with ISO 15501-1 and ISO 15501-2. The nozzle
shal l be suitable for the intended mode of use self service/fast f i l l /s low f i l l .
Adaptors and other types of connection f i tt ings shal l not be used.
13.3.3 Fi l l ing nozzles shal l be secured ag ainst inadvertent disconnection, e.g. by the
activation of a locking device. They shal l be constructed so that no one wi l l be
endangered even when disconnected under pressure.
13.3.4 When the f i l l ing nozzle is not in use, i t shal l be stored in a manner to prevent entry of
moisture and debris.
13.4 Captive vent systems
Where nozzle designs incorporate a system to col lect the smal l releases of gas on
connection/disconnection, they shal l be vented to a safe ar ea.
14 Electrical equipment and wiring
14.1 General
Where the equipment is placed i n a hazardous area, i t shal l comply with the appropriate
zoning rat ing as required in S I 60079 Part 10.01
14.2 Earthing protection
Care must be taken to ensure that al l conducting surfaces ( for example framework, piping
etc. ) shal l be adequately attached to a common earth according to the Israel i electr ic ity
regulat ions.
14.3 Lightning protection
Measures for protection against l ightning shal l comply with the requirements in S I 1173
Part 1.
15 Testing, purging and commissioning
15.1 The equipment ( i .e. compressors, valves, etc) shal l be strength tested. This can be
performed off-site by the manufacturers or contractor.
-
7/30/2019 Cng Fuelling Stations for Vehicles
43/72
Draft SI 6236 (2012)
36
All pressure loaded e quipment shal l be tested for strength and t ightness and adequately
purged before use as def ined in Annex E. Upstream of the compression unit ,
consideration should be given to instal l ing a temporary start-up (commissioning) f i l ter.
Documentation of al l tests, on and off-site, shal l be provided.
Al l tests shal l be performed by a competent person.
15.2 The compressor may need to be excluded from on-site test ing and purging according to
the manufacturer's instructions.
15.3 The system shal l be purged using a method such as described i n Annex H.
15.4 Commissioning of al l stat ion components and proper operation of al l safety equipment
shal l be undertaken by a competent person and documented.
16 Marking, operating notices and instructions
16.1 General
All markings and l i terature of a CNG fuel l ing stat ion shal l be in Engl ish.
Warning signs shal l c learly mark the area which is c lassi f ied as a hazardous area
indicating that smoking, naked l ights and the use of unprotected electr ical equipment are
prohibited.
Signs shal l be printed in Israel 's off ic ial languages and shal l include the relevant
pictograms.
Restr icted hazardous areas shal l be marked accordingly.
16.2 Marking
Fuel l ing stat ion components shal l carry the markings in a durable, legible manner on a
f irmly attached data plate that includes the fol lowing:
Identi f icat ion of the manufacturer and, where appropriate, identi f icat ion of his
authorized representative;
Year of manufacture;
Unique identif icat ion of the stat ion, such as type, serie s or batch identif icat ion
and/or serial number;
Essential l imits such as MOP and temperature;
-
7/30/2019 Cng Fuelling Stations for Vehicles
44/72
Draft SI 6236 (2012)
37
Operating pressure;
Rated power in kVA and supply voltage in V .
16.3 Dispenser signs
The dispenser shal l be c learly label led, indicating that i t d ispenses "CNG".
Warning signs shal l be placed adjacent to the area which is c lassi f ied as a hazardous area
indicating that smoking, naked l ights and the use of unprotected electr ic equipment are
prohibited.
Signs shal l be printed in Israel 's off ic ial languages.
16.4 Fuell ing instruction signs
For self -service fuel l ing stat ions, the fuel l ing instructions shal l be c learly displayed at
dispensing units adjacent to each f i l l ing hose. For other f i l l ing stat ions, the instructions
shal l be easi ly accessible for the personnel .
The instructions shal l include the relevant safety precautions especial ly no-smoking, turn
off engine, do not use cel l phone.
An emergency telephone number shal l be displayed as r equired in S I 5512 c lause 8.4.3.
An example of instructions are detai led in Annex C.
Instruction signs shal l be printed in Israel 's off ic ial languages and shal l include the
relevant pictograms.
16.5 Instructions
16.5.1 Instruction of employees
The fuel l ing stat ion operators and staff shal l be suitably trained in the operation of
equipment and in the emergency procedures.
16.5.2 Instal lat ion and operating instruction
Instal lat ion and operating instructions shal l be provided. They shal l i nclude at least
the fol lowing:
A recommendation to instal l an isolat ion valve between the gas supply and
metering pipework and the fuel l ing stat ion's in let connection;
Mounting, including assembling of dif ferent pieces of pressure equipment, i f any;
-
7/30/2019 Cng Fuelling Stations for Vehicles
45/72
Draft SI 6236 (2012)
38
How to put the stat ion into service;
Its proper operation;
Minimum requirements for maintenance including inspection by the operator such
as visual inspection of the f i l l ing hose and nozzle;
Compres