ngv filling stations · files\olkb\en_13638_(e)_070709.doc std version 2.2 cen/tc 326 date: 2007-07...
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Document type: European StandardDocument subtype:Document stage: Formal VoteDocument language: E
C:\Dokumente und Einstellungen\klaas\Lokale Einstellungen\Temporary InternetFiles\OLKB\EN_13638_(E)_070709.doc STD Version 2.2
CEN/TC 326
Date: 2007-07
prEN 13638:2007
CEN/TC 326
Secretariat: DIN
NGV filling stations
Tankstellen für mit Erdgas betriebene Fahrzeuge (NGV)
Stations service pour véhicules fonctionnant au gaz naturel (GNV)
ICS:
Descriptors:
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Contents Page
Foreword..............................................................................................................................................................6
Introduction ............................................................................................................................................6
1 Scope ......................................................................................................................................................7
2 Normative References...........................................................................................................................8
3 Definitions ............................................................................................................................................12
4 Symbols and Abbreviations ...............................................................................................................16
5 General provisions ..............................................................................................................................165.1 General..................................................................................................................................................165.2 Gas compressor...................................................................................................................................165.3 Gas storage ..........................................................................................................................................175.4 Mother daughter station......................................................................................................................175.5 Dispenser..............................................................................................................................................175.5.1 Components .........................................................................................................................................175.5.2 Filling methods ....................................................................................................................................175.5.3 Operation ..............................................................................................................................................175.6 Control systems...................................................................................................................................185.7 Dryer......................................................................................................................................................185.8 Gas cooling system.............................................................................................................................18
6 General principles of design and installation...................................................................................186.1 General construction...........................................................................................................................186.1.1 Materials ...............................................................................................................................................186.1.2 Prerequisites for the various elements of the assembly.................................................................196.1.3 Optional components..........................................................................................................................196.1.4 Permanent joining of components.....................................................................................................196.1.5 Working area ........................................................................................................................................206.1.6 Noise attenuation.................................................................................................................................206.1.7 Collision protection .............................................................................................................................206.1.8 Traffic management.............................................................................................................................206.1.9 Foundation ...........................................................................................................................................206.1.10 Unauthorized access...........................................................................................................................206.1.11 Requirements for the location of components.................................................................................206.1.12 Explosion protection measures .........................................................................................................206.1.13 Building regulations ............................................................................................................................216.1.14 Fire ........................................................................................................................................................216.1.15 Routine isolation..................................................................................................................................216.2 Gas composition..................................................................................................................................216.2.1 General..................................................................................................................................................216.2.2 Gas supplied to the filling station ......................................................................................................216.2.3 Gas supplied to the dispenser ...........................................................................................................216.2.4 Gas Composition during maintenance..............................................................................................216.3 Safety devices ......................................................................................................................................216.3.1 General..................................................................................................................................................216.3.2 Maximum allowed delivery pressure .................................................................................................226.3.3 Auxiliary safety devices ......................................................................................................................226.4 Delivery pressure and temperature to the vehicles .........................................................................226.5 Venting..................................................................................................................................................22
7 Location and layout of equipment .....................................................................................................237.1 General provisions ..............................................................................................................................23
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7.1.1 Location................................................................................................................................................237.1.2 Fire fighting..........................................................................................................................................237.2 Hazardous areas..................................................................................................................................237.3 Storage Facility (including ancillary equipment) .............................................................................237.4 Dispenser .............................................................................................................................................237.5 Enclosures ...........................................................................................................................................247.5.1 General Provisions..............................................................................................................................247.6 Canopies...............................................................................................................................................247.7 Restrictions and safety distances .....................................................................................................247.7.1 General Provisions..............................................................................................................................24
8 Gas supply, metering and composition ............................................................................................248.1 General Provisions..............................................................................................................................248.1.1 Connection to the gas supply ............................................................................................................248.1.2 Non-return system...............................................................................................................................248.1.3 Low inlet pressure...............................................................................................................................248.1.4 Special equipment...............................................................................................................................25
9 Gas compressor (including ancillaries) ............................................................................................259.1 General Provisions..............................................................................................................................259.1.1 Gas supplied from the compressor...................................................................................................259.1.2 Design...................................................................................................................................................259.1.3 Vibration ...............................................................................................................................................259.1.4 Pulsation...............................................................................................................................................259.1.5 Protection against weather.................................................................................................................259.1.6 Accessibility.........................................................................................................................................259.2 Gas recovery........................................................................................................................................259.2.1 General provisions ..............................................................................................................................259.3 Condensate drainage and disposal...................................................................................................259.4 Stage safety devices ...........................................................................................................................269.4.1 General provisions ..............................................................................................................................269.4.2 Relief Valve ..........................................................................................................................................269.5 Delivery line non-return valve ............................................................................................................269.6 Suction line components....................................................................................................................269.6.1 General provisions ..............................................................................................................................269.7 Instrumentation ...................................................................................................................................269.8 Markings...............................................................................................................................................279.9 Instructions ..........................................................................................................................................279.9.1 General .................................................................................................................................................279.9.2 Operation instructions ........................................................................................................................289.9.3 Servicing instruction...........................................................................................................................309.9.4 List of parts required for servicing....................................................................................................31
10 Storage facility (including ancillaries)...............................................................................................3110.1 Storage pressure vessels ...................................................................................................................3110.2 Pressure relief devices .......................................................................................................................3110.3 Emergency isolation valve .................................................................................................................3110.4 Pressure gauge....................................................................................................................................31
11 Station pipework and ancillary devices ............................................................................................3211.1 Station pipework..................................................................................................................................3211.2 Inlet pipework ......................................................................................................................................3211.3 Outlet pipework ...................................................................................................................................3211.3.1 General provisions ..............................................................................................................................3211.3.2 Above ground pipework .....................................................................................................................3211.3.3 Underground pipework .......................................................................................................................3211.3.4 Pipework in ducts................................................................................................................................3311.3.5 Flexible connections ...........................................................................................................................3311.4 Pressure gauges..................................................................................................................................3311.5 Pressure testing ..................................................................................................................................3311.6 Gas detection system .........................................................................................................................33
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12 Emergency shut down procedures....................................................................................................33
13 Dispenser..............................................................................................................................................3413.1 Dispensing unit ....................................................................................................................................3413.2 Filling hose ...........................................................................................................................................3413.3 Filling nozzle ........................................................................................................................................3513.4 Captive vent systems ..........................................................................................................................35
14 Electrical equipment and wiring.........................................................................................................3514.1 General..................................................................................................................................................3514.2 Earthing protection..............................................................................................................................3514.3 Lightning protection............................................................................................................................35
15 Testing, purging and commissioning................................................................................................35
16 Marking, operating notices and instructions....................................................................................3616.1 General..................................................................................................................................................3616.2 Marking .................................................................................................................................................3616.3 Signs .....................................................................................................................................................3616.4 Instruction signs ..................................................................................................................................3616.5 Instructions ..........................................................................................................................................3716.5.1 Instruction of employees ....................................................................................................................3716.5.2 Installation and operating instruction ...............................................................................................3716.5.3 Potential hazard ...................................................................................................................................3716.5.4 Emergency plan ...................................................................................................................................3716.5.5 Cooling Effects.....................................................................................................................................37
Annex A (informative) Examples: Hazardous areas .....................................................................................38A.1 Dispenser: ............................................................................................................................................39A.2 Storage and pressure vessels............................................................................................................40A.3 Compressors........................................................................................................................................41A.4 Venting devices....................................................................................................................................41A.5 Pipework ...............................................................................................................................................41A.6 Vehicles ................................................................................................................................................42
Annex B (informative) Safety distances.........................................................................................................43
Annex C (informative) Information on explosion protected equipment .....................................................44
Annex D (informative) Instructions for filling ................................................................................................45D.1 Filling procedure (for a typical fast-fill) .............................................................................................45D.2 Filling procedure (for a typical slow-fill) ...........................................................................................45D.3 Emergency plan instructions .............................................................................................................45
Annex E (normative) Hydrostatic and pneumatic testing.............................................................................46E.1 Testing ..................................................................................................................................................46E.1.1 First inspection ....................................................................................................................................46E.2 Hydrostatic strength/pressure test of system components ...........................................................46E.2.1 ...............................................................................................................................................................46E.2.2 ...............................................................................................................................................................46E.2.3 ...............................................................................................................................................................47E.2.4 ...............................................................................................................................................................47E.2.5 ...............................................................................................................................................................47E.2.6 ...............................................................................................................................................................47E.2.7 ...............................................................................................................................................................47E.3 Pneumatic leak test of the complete system ....................................................................................47E.3.1 ...............................................................................................................................................................47E.3.2 ...............................................................................................................................................................47E.3.3 ...............................................................................................................................................................47E.3.4 ...............................................................................................................................................................47E.3.5 ...............................................................................................................................................................47
Annex F (informative) Subsequent testing after commissioning................................................................48F.1 Obligation of registration and periodic inspections ........................................................................48
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Annex G (informative) Safety precautions for hydrostatic and pneumatic testing.......49G.1 Safety precautions ..............................................................................................................................49G.1.1 ...............................................................................................................................................................49G.1.2 ...............................................................................................................................................................49G.1.3 ...............................................................................................................................................................49G.1.4 ...............................................................................................................................................................49G.1.5 ...............................................................................................................................................................49G.1.6 ...............................................................................................................................................................49G.2 Special Drying......................................................................................................................................50
Annex H (informative) Purging........................................................................................................................51H.1 General provisions ..............................................................................................................................51H.2 Safety precautions ..............................................................................................................................51H.2.1 ...............................................................................................................................................................51H.2.2 ...............................................................................................................................................................51H.2.3 ...............................................................................................................................................................51H.2.4 ...............................................................................................................................................................51H.2.5 ...............................................................................................................................................................51H.2.6 ...............................................................................................................................................................51H.2.7 ...............................................................................................................................................................51H.3 Procedures...........................................................................................................................................51H.3.1 ...............................................................................................................................................................51H.3.2 ...............................................................................................................................................................52H.3.3 ...............................................................................................................................................................52
Annex I (informative) Example of filling plan with three bank system and two dispenser units.............53
Annex J (informative) Refuelling station – Informative diagram.................................................................54
Annex K (informative) Reference standards applied for materials in the construction of CNGfilling stations according to 6.1.1 not being CEN or ISO standards ..............................................55
Bibliography......................................................................................................................................................57
Annex ZA (informative) Clauses of this European Standard addressing essential requirements orother provisions of EU Directives......................................................................................................58
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Foreword
This document (prEN 13638:2007) has been prepared by Technical Committee CEN/TC 326 “Gas supply fornatural gas vehicles (NGV)”, the secretariat of which is held by DIN.
This document is currently submitted to the Formal Vote.
This document has been prepared under a mandate given to CEN by the European Commission and theEuropean Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA, B, C or D, which is an integral part of thisdocument.
Introduction
This standard provides requirements for the design, manufacturing, assembling, installation andtesting of Natural Gas vehicle filling stations.
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1 Scope
1.1 This standard covers the design, manufacturing, assembling, installation and testing of components andassemblies for compressed Natural Gas (CNG) vehicle filling stations filling natural gas vehicle tanks up to thenominal delivery pressure of 200 bar at 15C. It may be applicable for higher delivery pressures, having dueregard to the safety of operation of components, safety distances, mechanical strength and soundness testingof the installation.
1.2 It applies to filling stations supplied with normally distributed Natural Gas as defined in EN ISO 14532. Itwill be appropriate for other fuel gases, including those generated from landfill sites. However, the differentconstituent characteristics shall be recognised, in particular their possible consequent effect upon materialsand operations and their impact on the vehicles to be operated.
1.3 This standard includes all equipment from the inlet flange to the filling nozzle (i.e. the flange/jointseparating internal piping from the pipeline network, see Annex J). The filling station nozzles are consideredas the end point of the scope of the standard.
1.4 Filling stations to supply liquefied Natural Gas (LNG) or CNG from LNG are not covered by the scope ofthis standard.
1.5 Vehicle Refuelling Appliances (VRA) are covered by prEN 13945.
1.6 The scope of the standard includes refuelling stations of the following types (as shown in InformativeAnnex K):
On site fill
Fast fill
Private access
Public access (self-service or assisted)
Metered dispenser
Non metered dispenser
Mobile storage with or without on board compressor
The scope also includes general criteria concerning the following aspects:
a) Pressure adjustment due to temperature during refuelling;
b) Safety during filling;
c) Filling hose;
d) Storage;
e) Pressure control devices;
f) Distances between units;
g) Multifuel filling station;
h) Piping and cathodic protection;
i) Installation;
j) Final inspection and testing.
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2 Normative References
This European Standard incorporates, by dated or undated reference, provisions from other publications.These normative references are cited at the appropriate places in the text and the publications are listedhereafter. For dated references, subsequent amendments to or revisions of any of these publications apply tothis European Standard only when incorporated in it by amendment or revision. For undated reference, thelatest edition of the publication referred to applies.
EN 287-1 (2004) Qualification test of welders - Fusion welding - Part 1: Steels
EN 473 (2001) Non-destructive testing - Qualification and certification of NDT personnel - Generalprinciples
EN 682 (2002) Elastomeric seals - Materials requirements for seals used in pipes and fittings carryinggas and hydrocarbon fluids
EN 1012-1 (1996) Compressors and vacuum pumps; Safety requirements – Part 1: Compressors
EN 1127-1 (1997) Explosive atmospheres - Explosion prevention and protection - Basic concepts andmethodology.
EN 1964-1 (1999) Transportable gas cylinders - Specification for the design and construction of refillabletransportable seamless steel gas cylinders of water capacities from 0, 5 litre up toand including 150 litres - Part 1: Cylinders made of seamless steel with anR<(Index)m> value of less than 1100 Mpa
EN 1964-2 (2001) Transportable gas cylinders - Specification for the design and construction of refillabletransportable seamless steel gas cylinders of water capacities from 0, 5 litre up to andincluding 150 litres - Part 2: Cylinders made of seamless steel with an R<(Index)m>value of 1100 MPa and above
EN 10020 (2000) Definition and classification of grades of steel
EN 10021 (1993) General technical delivery requirements for steel and iron products
EN 10025-1 (2004) Hot rolled products of structural steels - Part 1: General technical delivery conditions
EN 10025-2 (2004) Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-alloy structural steels
EN 10025-3 (2004) Hot rolled products of structural steels - Part 3: Technical delivery conditions fornormalized/normalized rolled weldable fine grain structural steels
EN 10025-4 (2004) Hot rolled products of structural steels - Part 4: Technical delivery conditions forthermomechanical rolled weldable fine grain structural steels
EN 10025-5 (2004) Hot rolled products of structural steels - Part 5: Technical delivery conditions forstructural steels with improved atmospheric corrosion resistance
EN 10025-6 (2004) Hot rolled products of structural steels - Part 6: Technical delivery conditions for flatproducts of high yield strength structural steels in the quenched and temperedcondition
EN 10027-1 (2005) Designation systems for steels - Part 1: Steel names
EN 10027-2 (1992) Designation systems for steel; numerical system
EN 10028-1 (2002) Flat products made of steels for pressure purposes - Part 1: General requirements
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EN 10028-2 (2003) Flat products made of steels for pressure purposes - Part 2: Non-alloy and alloy steelswith specified elevated temperature properties
EN 10028-3 (2003) Flat products made of steels for pressure purposes - Part 3: Weldable fine grainsteels, normalized
EN 10028-4 (2003) Flat products made of steels for pressure purposes - Part 4: Nickel alloyed steels withspecified low temperature properties
EN 10028-5 (2003) Flat products made of steels for pressure purposes - Part 5: Weldable fine grainsteels, thermomechanically rolled
EN 10028-6 (2003) Flat products made of steels for pressure purposes - Part 6: Weldable fine grainsteels, quenched and tempered
EN 10028-7 (2000) Flat products made of steels for pressure purposes - Part 7: Stainless steels
EN 10083-1 (1996) Quenched and tempered steels - Part 1: Technical delivery conditions for specialsteels
EN 10083-2 (1996) Quenched and tempered steels - Part 2: Technical delivery conditions for unalloyedquality steels
EN 10083-3 (1995) Quenched and tempered steels - Part 3: Technical delivery conditions for boron steels
EN 10087 (1998) Free-cutting steels - Technical delivery conditions for semi-finished products, hot-rolled bars and rods
EN 10088-1 (2005) Stainless steels - Part 1: List of stainless steels
EN 10088-2 (2005) Stainless steels - Part 2: Technical delivery conditions for sheet/plate and strip ofcorrosion resisting steels for general purposes
EN 10088-3 (2005) Stainless steels - Part 3: Technical delivery conditions for semi-finished products,bars, rods, wire, sections and bright products of corrosion resisting steels for generalpurposes
EN 10204 (2000) Metallic products – Types of inspection documents
EN 10208-1 (1997) Steel pipes for pipe lines for combustible fluids - Technical delivery conditions - Part 1:Pipes of requirement class A
EN 10216-1 (2004) Seamless steel tubes for pressure purposes - Technical delivery conditions - Part 1:Non-alloy steel tubes with specified room temperature properties
EN 10216-2 (2004) Seamless steel tubes for pressure purposes - Technical delivery conditions - Part 2:Non-alloy and alloy steel tubes with specified elevated temperature properties
EN 10216-3 (2004) Seamless steel tubes for pressure purposes - Technical delivery conditions - Part 3:Alloy fine grain steel tubes
EN 10216-4 (2004) Seamless steel tubes for pressure purposes - Technical delivery conditions - Part 4:Non-alloy and alloy steel tubes with specified low temperature properties
EN 10220 (2002) Seamless and welded steel tubes - General tables of dimensions and masses per unitlength
EN 10222-1 (2002) Steel forgings for pressure purposes - Part 1: General requirements for open dieforgings
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EN 10222-3 (1999) Steel forgings for pressure purposes - Part 3: Nickel steels with specified lowtemperature properties
EN 10222-4 (2001) Steel forgings for pressure purposes - Part 4: Weldable fine grain steels with highproof strength
EN 10222-5 (1999) Steel forgings for pressure purposes - Part 5: Martensitic, austenitic and austenitic-ferritic stainless steels
EN 10277-1 (1999) Bright steel products - Technical delivery conditions - Part 1: General
EN 10277-2 (1999) Bright steel products - Technical delivery conditions - Part 2: Steels for generalengineering purposes
EN 10277-3 (1999) Bright steel products - Technical delivery conditions - Part 3: Free-cutting steels
EN 10277-4 (1999) Bright steel products - Technical delivery conditions - Part 4: Case hardening steels
EN 10277-5 (1999) Bright steel products - Technical delivery conditions - Part 5: Steels for quenching andtempering
EN 10297-1 (2003) Seamless circular steel tubes for mechanical and general engineering purposes -Technical delivery conditions - Part 1: Non-alloy and alloy steel tubes
EN 10305-1 (2002) Steel tubes for precision applications - Technical delivery conditions - Part 1:Seamless cold drawn tubes
EN 12007-1 (2000) Gas supply systems - Pipelines for maximum operating pressure up to and including16 bar - Part 1: General functional recommendations
EN 12007-2 (2000) Gas supply systems - Pipelines for maximum operating pressure up to and including16 bar - Part 2: Specific functional recommendations for polyethylene (MOP up to andincluding 10 bar)
EN 12007-3 (2000) Gas supply systems - Pipelines for maximum operating pressure up to and including16 bar - Part 3: Specific functional recommendations for steel
EN 12164 (2000) Copper and copper alloys - Rod for free machining purposes
EN 13445-1 (2002) Unfired pressure vessels - Part 1: General
EN 13445-2 (2002) Unfired pressure vessels - Part 2: Materials
EN 13445-3 (2002) Unfired pressure vessels - Part 3: Design
EN 13345-4 (2002) Unfired pressure vessels - Part 4: Fabrication
EN 13463-1 (2001) Non-electrical equipment for potentially explosive atmospheres - Part 1: Basic methodand requirements
EN 13480-1 (2002) Metallic industrial piping - Part 1: General
EN 13480-2 (2002) Metallic industrial piping - Part 2: Materials
EN 13480-3 (2002) Metallic industrial piping - Part 3: Design and calculation
EN 13480-4 (2002) Metallic industrial piping - Part 4: Fabrication and installation
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EN 13480-5 (2002) Metallic industrial piping - Part 5: Inspection and testing
EN 13480-6 (2002) Metallic industrial piping - Part 6: Additional requirements for buried piping
prEN 13945 (2000) NGV refuelling appliances
EN 60079-0 (2004) Electrical apparatus for potentially explosive atmospheres – Part 0: Generalrequirements
EN 60079-1 (2004) Electrical apparatus for potentially explosive atmospheres – Part 1: Flameproofenclosures “d”
EN 60079-7 (2003) Electrical apparatus for potentially explosive atmospheres – Part 7: Increased safety“e”
EN 60079-10 (2003) Electrical apparatus for explosive gas atmospheres – Part 10: Classification ofhazardous areas
EN 60079-11 (2006) Electrical apparatus for potentially explosive atmospheres – Part 11: Intrinsic safety “i”
EN 60079-14 (2003) Electrical apparatus for explosive gas atmospheres - Part 14: Electrical installations inhazardous areas (other than mines)
EN 60079-15 (2003) Electrical apparatus for explosive gas atmospheres - Part 15: Type of protection "n"
EN 60079-17 (2003) Electrical apparatus for explosive gas atmospheres - Part 17: Inspection andmaintenance of electrical installations in hazardous areas (other than mines)
EN 60079-18 (2004) Electrical apparatus for explosive gas atmospheres - Part 18: Construction, test andmarking of type of protection encapsulation "m" electrical apparatus
EN 60079-19 (2002) Electrical apparatus for explosive gas atmospheres - Part 19: Repair and overhaul forapparatus used in explosive atmospheres (other than mines or explosives)
EN 60079-26 (2004) Electrical apparatus for potentially explosive atmospheres – Part 26: Construction, testand marking of Group II Zone 0 electrical apparatus
CLC/TR EN 50054 (2003) Electrostatics - Code of practice for the avoidance of hazards due to staticelectricity
EN ISO 4126-1 (2004) Safety devices for protection against excessive pressure - Part 1: Safety valves
EN ISO 8434-1 (1997) Metallic tube connections for fluid power and general use - Part 1: 24° compressionfittings
EN ISO 8434-2 (1995) Metallic tube connections for fluid power and general use - Part 2: 37° flared fittings
EN ISO 8434-3 (1995) Metallic tube connections for fluid power and general use - Part 3: O-ring face sealfittings
EN ISO 8434-4 (2000) Metallic tube connections for fluid power and general use - Part 4: 24° coneconnectors with O- ring weld-on nipples
EN ISO 11120 (1999) Gas cylinders - Refillable seamless steel tubes water capacity between 150 l and3000 l – Design, construction and testing
EN ISO 14532 (2002) Natural gas – Vocabulary
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EN ISO 15403 (2000) Natural gas – Designation of the quality of natural gas for use as a compressed fuelfor vehicles
prEN ISO 15609-1 (2000) Specification and approval of welding procedures for metallic materials - Weldingprocedure specification - Part 1: Arc welding
EN ISO 15609-2 (2001) Specification and qualification of welding procedures for metallic materials -Welding procedure specification - Part 2: Gas welding
ISO 683-1 (1987) Heat-treatable steels, alloy steels and free-cutting steels; Part 1: Direct-hardeningunalloyed and low alloyed wrought steel in form of different black products
ISO 9809-1 (1999) Gas cylinders - Refillable seamless steel gas cylinders - Design, construction andtesting - Part 1: Quenched and tempered steel cylinders with tensile strength less than1100 MPa
ISO 9809-2 (2000) Gas cylinders; Refillable seamless steel gas cylinders - Design, construction andtesting - Part 2: Quenched and tempered steel cylinders with tensile strength greaterthan or equal to 1100 MPa
ISO 9809-3 (2000) Gas cylinders - Refillable seamless steel gas cylinders; Design, construction andtesting - Part 3: Normalized steel cylinders
ISO 14469 (2005) Road vehicles - Compressed natural gas (CNG) refuelling connector - Part 1: 20 MPa(200 bar) connector
ISO 15501–1 (2001) Road vehicles – Compressed natural gas (CNG) fuel systems – Part 1: Safetyrequirements
ISO 15501–2 (2001) Road vehicles – Compressed natural gas (CNG) fuel systems – Part 2: Test methods
3 Definitions
For the purpose of this standard, the following definitions apply:
3.1assemblysub-system of CNG filling stations comprising several components, e.g. a container with the compressor andstorage unit
3.2buildingstructure that cannot be defined as an open building
3.3burst pressure (pb)pressure which causes failure and consequential fluid loss through the component envelope
3.4break-away devicedevice which, when activated, stops gas flow from the dispenser (for example if the vehicle moves away)while still connected to the refuelling hose
3.5canopya roof, for example a shelter, a hood etc., which affords a degree of weather protection
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3.6cascade dispensing sequencemeans of allowing efficient use of the gas storage facility by dividing it into banks operating at differentpressure levels
3.7competent personperson having the ability, appropriate training, knowledge and experience, to supervise or carry out the workbeing undertaken in a safe and proper manner
3.8compression unitunit that compresses the natural gas consisting of one or more compressors, including all piping andequipment
3.9compressormachine which increases the pressure of gas from a low to a higher level
3.10cylinderany vessel used for the storage of compressed natural gas
3.11blow down vesselvessel which receives compressed gas from the high pressure section of the installation and conducts it to theinput of the compression system. Also serves to collect the eliminated liquids
3.12dispenserthe equipment through which the compressed natural gas is supplied to the vehicle
3.13dryersystem which decreases the water content of natural gas
3.14enclosuredesignated structure, not a building, but which may be a housing, a room, a container etc., which encloses acomponent of the station
3.15explosive gas atmospheremixture with air, of a flammable material in the form of gas or vapour in which, after ignition, combustionspreads throughout the unconsumed mixture
3.16fast fillfilling operation which is comparable in duration to that of liquid fuel
3.17filling stationlocation at which gas is dispensed into a vehicle storage pressure vessel
3.18fire wallwall, screen or separating partition erected in the open air to reduce the effects from radiated heat and toensure an adequate dispersion distance for Natural Gas leaking from any vessel
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3.19gas conditioning equipmentequipment to filter and/or remove unwanted constituents (moisture, debris, liquid and vapours) from gaseither prior to or after compression
3.20hazardous areaarea in which an explosive gas atmosphere is present, or may be expected to be present, in quantities suchas to require special precautions for the construction, installation and use of apparatus
3.21liquid separatordevice which causes any liquids within the gas to drop out of suspension for collection. A liquid separator canbe placed after compression of the natural gas
3.22lower explosive limit (LEL)the concentration of flammable gas or vapour in air below which the gas atmosphere is not explosive. Fornatural gas containing only methane the LEL is 5.5 % by volume. For example 10 % LEL means 0.55 % gasin air
3.23maximum allowable pressure ( pS)maximum pressure for which the system is designed, as specified by the manufacturer
3.24overpressurepressure above the maximum allowable pressure which shall be prevented by safety devices
3.25delivery pressurepressure at which the gas is delivered to the vehicle
3.26nominal delivery pressurepressure at which filling automatically stops
3.27maximum delivery pressuremaximum pressure acceptable by the vehicle to be filled
3.28mobile storagemulti-cylinder or tank fixture permanently mounted on a special vehicle and used for the transportation ofnatural gas to other refuelling stations (see mother -daughter)
3.29mother-daughtera station not connected to the pipeline (daughter) where gas is supplied by road transport from a stationconnected to the pipeline (mother). The transport arrangements are regulated by the ADR Directive (seemobile storage)
3.30natural gasa gaseous fuel containing a mixture of hydrocarbons, primarily methane, but generally also including ethane,propane and other hydrocarbons. It generally also includes some inert gases, such as nitrogen and carbondioxide, plus trace constituents
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3.31normal operationsituation when the equipment is operating within its design parameters
3.32non-hazardous areaarea in which an explosive gas is not expected to be present in quantities such as to require specialprecautions for the construction, installation and use of apparatus
3.33open buildingconstruction, in which the same ventilation conditions are present as in the open air and no obstruction fornatural air circulation is present
3.34on site fillingfilling where many vehicles are connected at the same time for several hours
3.35primary grade of releaserelease of gas which is likely to occur under normal operation
3.36recovery vesselvessel that recovers gas from the compressor and its ancillaries and which may also serve to damp outpressure pulsations in the compressor inlet
3.37safety distancedistance between the filling station, its components and structures and other installations and structures in thevicinity. This distance reduces the degree of danger in the case of an incident
3.38secondary grade releaserelease of gas which is unlikely to occur in normal operation and will have only a limited duration
3.39slow fillfilling operation which takes, typically, several hours
3.40storageany number of suitable compressed natural gas storage containers designed for the purpose of containingand subsequently releasing compressed natural gas
3.41test pressure (pt)pressure to which the installation or part of installation, is tested. Different levels may be required for storagepressure vessels and other components
3.42ventilationmovement of air and its replacement with fresh air due to the effects of wind, temperature gradients, orartificial means (for example fans or extractors)
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3.43vehicle refuelling appliance(VRA)natural gas compressor package not containing storage , having a flow rate not exceeding 20 m3/hr (stp) atstandard conditions with a max. gas outlet pressure of 260 bar and with a max. gas containment 0.5 sm3 (stp)and intended for unattended refuelling of vehicles, having a properly installed containment system
3.44zoneshazardous areas are classified into zones based upon the frequency of the occurrence and duration of anexplosive gas atmosphere
3.44.1zone 0area in which an explosive gas atmosphere is present continuously or for long periods
3.44.2zone 1area in which an explosive gas atmosphere is likely to occur in normal operation
3.44.3zone 2an area in which an explosive gas atmosphere is not likely to occur in normal operation and, if it does occur, islikely to do so only infrequently and will exist for a short period only
4 Symbols and Abbreviations
ADR (see Annex M)
PED Pressure equipment directive 97/23/EC
pb burst pressure
pS Maximum allowable pressure
pt Test pressure
LEL Lower explosive limit
CNG Compressed natural gas
NGV Natural gas vehicle
5 General provisions
5.1 General
A comprehensive scheme of possible components is shown as an example in the diagram Annex I(informative). For all components of an NGV filling station, the manufacturer shall provide proof of theirconformity to specification. They shall be identified in such way as to provide proof of traceability
5.2 Gas compressor
In general, gas compressors for Natural Gas filling stations produce high pressure lifts. A compressor maysupply either bulk storage and/or a direct filling facility. A typical compressor, for example would be a multi-
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stage machine which may be directly or indirectly driven by an electric motor or an internal combustionengine. The compressor shall be in compliance with the requirements of EN 1012-1 standard.
5.3 Gas storage
A certain volume of gas may be stored to facilitate fast filling of vehicles. For example, storage is provided inbanks of multiple vessels to speed up filling, to optimise the station design and to limit the number of start/stopcycles of the gas compressor.
5.4 Mother daughter station
All components of the stationary parts of this type of station have to comply with this standard. Duringtransportation the mobile storage with or without on board compressor shall comply to ADR regulations. In allother situations this standard applies.
5.5 Dispenser
5.5.1 Components
A dispenser comprises for example:
a dispensing and optional metering unit;
a filling hose;
a filling nozzle.
Gas for dispensing is drawn either directly from a compressor or via on-site storage, and then passed into thevehicle.
5.5.2 Filling methods
Vehicle filling can be undertaken in the following ways:
a) Fast-fill;
b) On site fill/slow fill;
c) With or without temperature compensation, taking into account the climatic condition (temperature range),and any other elements such as: safety factor of cylinder, cylinder material, thermal insulation material (ifany). These items shall be take into consideration during design stage.
If slow-fill facilities are unattended during the filling operation, then the installation of extra safety and securitysystems may be necessary.
5.5.3 Operation
The dispenser can be operated in several forms, for example:
a) Manually or automatically operated;
b) Metered or unmetered;
c) A fill-post, which is used mainly for on site fill stations;
d) Assisted or self-service
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5.6 Control systems
A control system operates the compressor and/or any storage facility in conjunction with the demands of thedispenser.
5.7 Dryer
A drying system may be required to control the water content of the gas to comply with relevant standards.See ISO 15403.
5.8 Gas cooling system
If a system is required to control the delivered gas temperature, it shall be designed in such a way to take intoaccount the climatic condition (temperature range) and any other elements such as: safety factor of cylinder,cylinder material, thermal insulation material (if any).
6 General principles of design and installation
6.1 General construction
All equipment, components, pipework, fittings and materials shall be of a type and manufacture and beassembled in such manner suitable for their intended use, for the full range of pressures, type of gas,temperatures, weather conditions and loadings which may occur under normal and fault conditions. Theseshall be supported by appropriate certification (for example EN 10204). These shall be installed and used inaccordance with the manufacturer's instructions.
Consideration shall be given to depressurisation of pressurized components e.g. for removal for maintenancepurposes, draining condensate, by the provision of valves and gauges to ensure that sections aredepressurised before service interventions.
6.1.1 Materials
The following standards when used in conjunction with the relevant design code such as, but not limited tocurrent versions of those listed in informative annex K may be acceptable, but will not automatically fulfil therequirements of directive 97/23/EC.
The manufacturer of the station shall ensure that all material used for the construction of the station conformsto the required specifications. In particular, documentation provided by the material manufacturer affirmingcompliance with the specification must be obtained for all materials used for the production of pressurecarrying components. For the main pressure-bearing parts this shall take the form of a certificate of specificproduct control in accordance with EN 10204 prepared by the material manufacturer affirming compliance withthe material specifications within this sub-clause.
The manufacturer of the station shall document the compliance with the design and material specifications. Heshall use one or more of the appropriate standards as used for the construction of pressurized parts. Thesematerials shall:
a. have suitable properties for all operating conditions which are reasonably foreseeable and for all testconditions. In particular, they should be sufficiently ductile and tough. Moreover, due care should beexercised in particular in selecting materials in order to prevent brittle-type fracture where necessary;
b. be chemically resistant to delivered quality natural gas, and, if applicable, to regenerative producedgases;
c. not be significantly affected by ageing;
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d. be resistant to corrosion or, alternatively, protected against corrosion by suitable coating;
e. be suitable for the intended pressures and temperatures and the variations thereof;
f. be selected in order to avoid significant undesirable effects when the various materials are puttogether.
Compliance with the design and material specifications of the pressure equipment directive is given by one ofthe following standards
EN 682 for elastomeric material and
EN 10208-1, EN 10216-1, EN 10216-2, EN 10216-3, EN 10216-4, EN 10220, EN 10297-1, EN 10305-1,EN 13480-1, EN 13480-2, EN 13480-3, EN 13480-4, EN 13480-6, EN ISO 8434-1, EN ISO 8434-2, ENISO 8434-3, EN ISO 8434-4 for the stations’ piping,
EN 10020, EN 10021, EN 10025-1, EN 10025-2, EN 10025-3, EN 10025-4, EN 10025-5, EN 10025-6, EN10027-1, EN 10027-2, EN 10028-1, EN 10028-2, EN 10028-3, EN 10028-4, EN 10028-5, EN 10028-6,EN 10028-7, EN 10083-1, EN 10083-2, EN 10083-3, EN 10087, EN 10088-1, EN 10088-2, EN 10088-3,EN 10222-1, EN 10222-3, EN 10222-4, EN 10222-5, EN 10277-1, EN 10277-2, EN 10277-3, EN 10277-4, EN 10277-5, EN 12164, EN 13445-1, EN 13445-2, EN 13445-3, EN 13445-4, ISO 683-1 for pressurevessels,
EN 1964-1, EN 1964-2, EN ISO 11120, ISO 9809-1, ISO 9808-2, ISO 9809-3 for steel cylinders of thestorage unit.
The standards when used in conjunction with the relevant design code such as, but not limited to currentversions of those listed in informative annex K may be acceptable, but will not automatically fulfil therequirements of European directive 97/23/EC.
6.1.2 Prerequisites for the various elements of the assembly
These shall not only be appropriate to their normal functioning but also take into account the effect ofextraneous forces such as the effects of changes in temperature, and forces and vibrations set up duringmanufacturing and assembly. This implies proof of adequate strength either by calculation method or byexperimental design method. All the elements of assembly shall be protected against corrosion by means ofsuitable systems, such as painting, and/or cathodic protection, taking into account environmental conditions.
6.1.3 Optional components
Optional components (e.g. dryers and chillers) shall not impair the operability and safety of the filling station.
6.1.4 Permanent joining of components
Permanent joints and adjacent zones shall be free of any surface or internal defects detrimental to the safetyof the system. The properties of permanent joints must meet the minimum properties specified for thematerials to be joined unless other relevant property values are specifically taken into account in the designcalculations.
Any joining of components may only be performed by a competent person. In particular, welded connectionsmay only be produced by a welder qualified in accordance with the EN 287-1. The welding shall be carried outto a procedure as specified in EN ISO 15609-1 or EN ISO 15609-2 taking into account any necessary heattreatment and traceability of materials.
Permanent joints shall be subject to non-destructive tests carried out by suitably qualified personnel, e.g. incompliance to EN 473.
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6.1.5 Working area
A sufficient working area for checking, maintenance and service shall be available.
6.1.6 Noise attenuation
Control of noise shall comply with local legislation and site requirements.
6.1.7 Collision protection
The refuelling station components shall be adequately protected against collision of vehicles. Specialconsideration shall be given to collision protection of the storage and dispenser.
6.1.8 Traffic management
Consideration should be given to the flow of vehicles on the station premises.
6.1.9 Foundation
The natural gas refuelling station shall be mounted on adequate foundations.
6.1.10 Unauthorized access
There shall be adequate means such that safety of operation cannot be affected by unauthorized access.
6.1.11 Requirements for the location of components
Equipment shall be located preferably in open air or dedicated buildings. In all other cases due considerationshall be given to safety and ventilation requirements.
Electric and non-electrical equipment and/or components shall be either explosion protected or located inareas without presence of potentially explosive atmosphere (safe area).
6.1.12 Explosion protection measures
Explosion protection measures shall be taken in accordance with EN 1127-1 and Annex D of EN 13638-1.
All electrical and non-electrical equipment and components, intended for use in potentially explosiveatmospheres (hazardous area), shall be designed and manufactured according to good engineering practiceand in conformity with the required categories for group II equipment, to ensure avoidance of any ignitionsource, as mentioned in EN 1127-1.
Equipment and components shall be suitable as a minimum requirement for Explosion Group IIA andtemperature class T3 as defined in EN 60079-0 and EN 13463–1.
Electrical installations used in potentially explosive atmospheres shall comply with the requirements of 14.1.
Non-electrical equipment used in potentially explosive atmospheres shall comply with the requirements of EN13463 – 1.
Light alloy when used shall conform to the requirements of EN 13463–1. If other specifications for explosionprotected equipment impose more stringent requirements then more stringent requirement shall apply.
All equipment/component shall be adequately connected to a common earth; the resistance between themeasured point and the main PE terminal shall be less than 0,1 Ω (1 V voltage drop).
Measures shall be taken into account to avoid electrostatic risk.
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In order to prevent discharges between filling nozzle and filling hose, materials shall be selected to ensure thatthe resistance between nozzle and earth is less than 106 .
Other non conductive surfaces shall have a surface resistance according to the requirements of EN 13463–1.
6.1.13 Building regulations
Consideration shall be given to local building regulations.
6.1.14 Fire
Consideration shall be given to fire protection.
6.1.15 Routine isolation
A manual isolation valve shall be fitted 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
Natural gas delivered by the filling station shall be odorised according to local regulations.
6.2.2 Gas supplied to the filling station
The equipment of the station shall be suitable for the gas supplied.
6.2.3 Gas supplied to the dispenser
Gas supplied to the filling nozzle shall have a particulate matter level which will not cause malfunction of thedispensing equipment and shall comply with ISO 15403.
6.2.4 Gas Composition during maintenance
Any maintenance or servicing anticipated during operation of the filling station shall not affect adversely thecomposition of gas supplied from the station.
6.3 Safety devices
6.3.1 General
Filling stations shall be equipped with safety devices that prevent overpressure in any part of the filling stationand its pipework, and the uncontrolled release of pressurized gas. However, a short duration increase to 1,1times the maximum allowable pressure is permissible.
Safety devices shall be independent of other functions, unless their safety function cannot be affected by suchother functions. They shall comply with appropriate design principles in order to obtain suitable and reliableprotection.
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6.3.2 Maximum allowed delivery pressure
The natural gas dispensing system shall be equipped with an automatically operated safety device, which willwork in such a way that the delivery pressure to the vehicle cannot exceed the maximum allowed deliverypressure.
6.3.3 Auxiliary safety devices
Auxiliary safety devices shall include at least:
an automatic emergency gas isolation valve which isolates;
dispenser(s);
the station;
storage;
an emergency stop button.
6.4 Delivery pressure and temperature to the vehicles
In no case the pressure of the installation in the vehicle shall, once disconnected from the dispenser, exceed260 bar irrespective of the ambient temperature.
The maximum delivery pressure of the natural gas to the vehicle shall not exceed 200 bar above atmosphericpressure for refuelling stations without temperature compensation. It may be higher where temperaturecompensation is used (this may be required by local regulation.)
The temperature of the gas delivered to the vehicle shall be such that in any case the limits of –40°C and+65°C are not exceeded.
The filling station has to control the filling of the vehicle in such a way as to obtain an on board gas mass notexceeding the mass corresponding to a storage at 200 bars and 15 °C.
6.5 Venting
Where relief valve vents are manifolded together, operation of any relief shall not be impeded.
Venting shall not be possible into enclosures.
Safety relief valves shall vent to the atmosphere and the vent pipe shall:
a) be upward facing and be unimpeded;
b) the discharge of natural gas from venting safety devices shall take place at a safe place outdoors at aheight of at least 3 m above the ground, and at least 1 m higher than any buildings within a radius of 5m;
c) be designed to take account of the adverse effects of rain, condensation, foreign bodies and rust.
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7 Location and layout of equipment
7.1 General provisions
Site location and layout shall be planned carefully as most of the site components have location restrictionsand minimum safety distances and may be affected by "hazardous area" requirements.
These restrictions may only be reduced where special measures are taken to remove the hazard asmentioned in EN1127-1.
7.1.1 Location
Location should be preferably in the open air and in a well ventilated position, but under certain conditions in aroom or building.
7.1.2 Fire fighting
Consideration shall be given to accessibility by fire fighters and their equipment.
7.2 Hazardous areas
7.2.1 A hazardous area classification analysis shall be undertaken for the location of electrical and othersources of ignition. Special attention must be given to existing equipment such as high voltage cables.
The classification shall be in accordance with the European standard EN 60079-10.
7.2.2 Hazardous areas may have to be provisionally determined at an early stage in a project to allowelectrical equipment to be specified and other potential sources of ignition to be located. However, a completedrawing shall be produced prior to installation of the filling station and shall be based on Annex B. This annexis based on European standard EN 60079-10.
7.2.3 New and existing installations shall both comply with EN 60079 – 10 when affected by new hazardousareas.
7.2.4 The hazardous area shall not exceed the boundary of the filling station unless a complementary riskanalysis is carried out.
7.3 Storage Facility (including ancillary equipment)
7.3.1 Installation shall be in a well ventilated location, ideally in the open air.
In addition, the base of the facility shall be designed to prevent the collection of liquids, for example water,liquid fuels etc., beneath the storage pressure vessels.
7.3.2 Adequate access, including overhead if appropriate, should be given to permit removal of individualbanks of vessels, dependent upon design, to allow revalidation. Consideration shall be given to the protectionof manifold pipework during removal of vessels.
7.4 Dispenser
7.4.1 Dispensers shall be positioned so that vehicles have adequate space for manoeuvring into and out ofthe filling position.
7.4.2 Where a slow-fill facility is provided, adequate protection shall be given against unauthorisedinterference, particularly during periods of unmanned filling operations.
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7.4.3 The dispenser shall comply with the hazardous area classification of the area where the dispenser isplaced, taking into account as specified in EN1127-1 standard and the construction of the dispenser itself.
7.5 Enclosures
7.5.1 General Provisions
It is preferable to install any compressor or storage facility in the open air. However, where this may haveunacceptable aspects, for example safety, security, noise levels, weather protection etc., consideration maybe given to the use of an enclosure, with a suitably designed ventilation system.
7.5.1.1 A compressor and storage facility, including their respective ancillaries, may be housed in thesame compartment.
7.5.1.2 An enclosure used to house a compressor and/or a storage facility, including their respectiveancillaries, shall not be used for any other purpose.
7.6 Canopies
Any canopy shall not inhibit natural ventilation and shall be designed to prevent the accumulation of anypotential gas release.
7.7 Restrictions and safety distances
See Annex B, Annex C.
7.7.1 General Provisions
If a fire wall is constructed, thus reducing the minimum safety distances, it shall be of at least 1 hour fire-resistant construction, impermeable and of solid masonry or concrete. The wall shall be at least as high as thehighest component and have a minimum height of 2 m.
8 Gas supply, metering and composition
8.1 General Provisions
Consideration shall be given to the effects of the operation of a compressor on the local gas supply network.
8.1.1 Connection to the gas supply
When planning the installation of a CNG filling station it shall be sure that the capacity of the gas supplynetwork shall be sufficient to cope with the gas compressor suction requirements, and compressor operationshall not create problems of low flow rate, low pressure, or pulsation, for the gas pipeline system.
8.1.2 Non-return system
A non-return system shall be fitted immediately downstream of the meter. The system should consist of, as aminimum, two devices, for example a non-return device and a pressure operated slam-shut.
8.1.3 Low inlet pressure
A safety device as e.g. a pressure switch shall be mounted which in case the inlet gas pressure to thecompressor falling below an acceptable level, shall act onto the compressor to shut down and not to re-startautomatically.
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8.1.4 Special equipment
It may be necessary to provide gas conditioning equipment, filters and pressure regulation which shall bedesigned and constructed to appropriate standards.
The system shall be designed such that any element can be exchanged safely and easily.
9 Gas compressor (including ancillaries)
9.1 General Provisions
9.1.1 Gas supplied from the compressor
The gas supplied from the compressor shall not cause malfunction of equipment after the compressor inrespect of temperature, corrosion and blockage.
9.1.2 Design
The compressor(s) shall be designed for safe operation and should be capable of continuous full load duty(see EN 1012-1)
9.1.3 Vibration
The compressor(s) shall be provided with adequate means of balancing, support or mounting to minimise thetransmission of mechanical vibration to the structure. The inlet and outlet connections of the compressor(s)should be designed to prevent the transmission of vibration.
9.1.4 Pulsation
The compressor(s) shall be provided with a suitable device which protects the system from unacceptablepressure pulsations.
9.1.5 Protection against weather
A compressor intended for outdoor installation has to be adequately protected against weather conditions toensure safe and reliable operation.
9.1.6 Accessibility
Components, integral parts and user controls that may require adjustment or replacement during servicing,operation and maintenance shall be easily accessible.
9.2 Gas recovery
9.2.1 General provisions
Consideration should be given to recovery of gas released from separators.
9.3 Condensate drainage and disposal
A safe and controlled system shall be used to facilitate liquid removal from the point of condensate collection.In particular, any pressure relieved during this action shall not cause any danger to the operator or any otherperson.
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9.4 Stage safety devices
9.4.1 General provisions
Each stage of compression should be equipped with a safety device to prevent overpressurising (i.e. by asafety valve or pressure switch). A safety valve shall be provided for the final stage of the compressor (see EN1012-1).
NOTE: Each stage of compression should be equipped with a safety device to prevent overpressurising (i.e. by a safetyvalve or pressure switch).
The compressor system shall be fitted with indicators of the following parameters:
inlet pressure;
outlet temperature after the final stage;
and when applicable:
lubricant pressure/level;
hydraulic oil pressure level;
temperature of cooling fluid.
9.4.1.2 Resetting of the control system shall be undertaken manually.
9.4.2 Relief Valve
The final stage shall have a full capacity relief valve which may vent to atmosphere or may vent to a recoveryvessel, which itself shall have a relief valve.
9.5 Delivery line non-return valve
A suitable non-return device shall be fitted to the compressor discharge line to prevent loss of downstreampressure when the compressor is unloading and when the liquid separator is draining.
9.6 Suction line components
The procedures discussed in this sub clause are additional to those given in clause 8.
9.6.1 General provisions
A normally closed valve shall be fitted to isolate the gas supply to the compressor whenever the compressor isnot running.
9.7 Instrumentation
9.7.1 An hours run meter shall be provided.
9.7.2 The compressor system shall be fitted with shutdown devices in the event of the following:
low gas inlet pressure
high gas inlet pressure if exceeding the compressor inlet pressure can occur;
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high gas outlet pressure;
high outlet gas temperature at the final stage;
and when applicable:
low lubricant pressure/level;
high hydraulic oil temperature ;
low hydraulic oil level ;
high temperature of cooling fluid.
Other adverse conditions may need to be taken into account.
9.7.3 Indicators shall be provided to show that the electrical supply is "on" and that the motor is running.
9.7.4 The compressor(s) shall shut down safely in the event of loss of energy supply.
9.8 Markings
A compressor shall be marked by the manufacturer. It shall carry the following markings in a durable, legiblemanner on a firmly attached plate:
identification of the manufacturer and, where appropriate, identification of his authorizedrepresentative;
the year of manufacture;
unique identification of the compressor, such as type, series or batch identification and/or serialnumber;
essential limits such as maximum allowable pressures and temperature, rated power in kW(kilowatts) and supply voltage in V (Volts);
maximum allowable pressure of the compressor;
warning or special conditions for safe use.
9.9 Instructions
9.9.1 General
The compressor(s) shall be provided with comprehensive instructions enabling its designated operation.These shall describe procedures for the safe operation and for maintenance, and they shall contain warningsconcerning known hazardous practices, undesignated use and residual risks.
The documentation shall be provided by the manufacturer. When brought into service, for all compressors theinstructions shall be present in the original language and in translation into one of the official languages of thecountry of operation.
The translation may be produced by the manufacturer, by its authorized representative or by the personimporting the equipment into the relevant language region.
The texts shall be simple, appropriate, complete and suitable for the personnel in charge of the compressor.
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Merchandise material describing the compressor shall not be in contradiction to the operation instructions inview of safety matters.
The documentation delivered with the compressor shall reflect its complexity and consist of the following:
a) An operations instruction delivered with all compressors, providing instructions to the owner andto the operating personnel.The operations instruction shall be kept at the compressor, accessible to the operating personnel.
b) A servicing instruction, providing instructions for the work of specially instructed personnel.
c) A list of parts required for service
The information contained in these documents may be contained in more than one document.
9.9.2 Operation instructions
This document shall contain the following:
9.9.2.1 The same instructions as the data plate
9.9.2.2 Drawings, diagrams, instructions and information
about:
a) Installations and assembly;
b) Disconnection from electric power supply for the compressor, if required;
c) Commissioning;
d) Switch off;
e) Decommissioning;
f) Handling and lifting e.g. of the mass of the compressor or of the major components;
g) Adjustment and calibration.
9.9.2.3 Information concerning the application
a) Fluids for which the compressor is designated;
b) Inlet, internal and outlet temperatures;
c) Inlet, internal and outlet pressures;
d) Maximum pressure difference;
e) Specifications for lubricants and filters in view of quality, amount and recommended replacementintervals;
f) Specifications of hydraulic oils;
g) Pressure and temperature limits of the lubrication system;
h) Environmental condition limits;
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i) Maximum and eventually minimum revolution number;
j) The necessity to install pressure relief devices and other protective devices if they are not part ofthe delivery of the compressor;
k) A warning to operate the compressor eventually in an explosive atmosphere unless it is designedfor such purpose. In that case information shall be provided about necessary safety measures;
l) How to collect contaminated condensate effectively and how to dispose of safely;
m) Information about operation of the compressor at an ambient temperature below 0°C:
Safety measures to prevent ice and snow to affect the operation of the compressor, inparticular that pressure relief devices, intake air filters for the compressor and for air coolingmay be clogged;
Measures to be taken to prevent the freezing of water cooling systems, water separators,valves and controls;
Measures to prevent the freezing of condensate accumulations;
Measures to protect the control system against operational failure;
Specification of lubricants for low temperatures or measures to be taken to keep thelubrication system warm.
9.9.2.4 Information concerning the operation
including:
a) Start and stop of the compressor;
b) Emergency stop device, its positioning, functioning and use;
c) Guidelines for simple trouble shooting;
d) Operation only with lids and doors closed if the compressor is designed for such operation;
e) Remote control of the compressor;
f) Symbols used (see e.g. EN 1012-1, informative annex C);
g) Routine inspections, cleaning and maintenance work including the cleaning of radiators, refill jobsand the exchange of simple parts as e.g. air or oil filters;
h) Recommendation to wear ear protection if appropriate;
i) Position of extensive hot or cold surfaces;
j) Risk to inhale hazardous gases, fogs or steams;
k) Risk of formation of oil coal in supply piping;
l) Measures required for the protection of the operating personnel against residual risks.
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9.9.2.5 Decommissioning
Information about the safe decommissioning is given in EN 626.
9.9.2.6 Delineation of the working area
if applicable
9.9.2.7 Noise
It shall be referred to the requirements in 1.7.4f of annex A of EN 292-2.
9.9.2.8 Training
Requirements for the training of the operational personnel shall be provided.
9.9.2.9 Instructions for special types of compressors: gas compressors
If a hazard exists due to decomposition of the gas or to an internal explosion and if the compressor is notdesigned such to resist the pressures resulting thereof a warning shall be given and the location where thecompressor is installed shall be declared as a hazard zone.
Information about appropriate flushing of pipelines and accessories connected shall be provided.
9.9.3 Servicing instruction
The servicing instruction shall outline those duties to be performed by specially trained personnel. Theseduties are in addition to the routine inspections, cleaning and maintenance work listed in 9.9.2.4g).
The servicing instruction shall contain the following
The same information as given on the data plate;
Drawings and diagrams required for periodical maintenance and simple repairs;
List of components and parts subject to wear and tear requiring regular inspection or regularexchange;
Guidelines for trouble shooting;
Schedule for regular inspection and exchange of components and parts subject to wear and tear;
Guidelines for the safe execution of maintenance work and subsequent testing in compressorstations with more than one compressor;
Guidelines for the safe commissioning, decommissioning and partition of each unit in a compressorstation with more than one compressor;
Address of the service station(s) authorized by the manufacturer;
Warning that only one safety function may be out of service at one time for the purpose of inspection,maintenance and repair.
NOTE: In addition to the servicing instruction provided with each compressor the manufacturer usually will only provide arepair manual exclusively for his authorized service personnel in a language, describing all the special duties required fora general overhaul and for repair works of the compressor system.
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9.9.4 List of parts required for servicing
The manufacturer shall provide a list giving information about all relevant parts for servicing, withunmistakeable identification and indicating the location of their installation at the compressor.
10 Storage facility (including ancillaries)
10.1 Storage pressure vessels
10.1.1 Any storage pressure vessel shall comply with EN 13445-1, EN 13445-2, EN 13445-3, EN 13445-4and EN 13445-5.
10.1.2 Means shall be provided to prevent any pressurised vessel from being isolated from its pressure reliefdevice. For example for cylinders without their own pressure relief device this can be achieved by the removalof any isolation valve handle and the adoption of formal procedures to take any individual vessel out ofservice.
10.1.3 Precautions shall be taken in order to protect the storage facility from heat radiation (i.e. sunradiation).
10.2 Pressure relief devices
10.2.1 At least one suitable non temperature dependent safety device shall be fitted to protect the storagefrom over-pressurisation with a discharge rate that is adequate to ensure a controlled depressurisation of thesystem.
10.2.2 A suitable device that releases the pressure at a temperature of 100 ºC +/- 10°C when using steelpressure vessels shall be fitted to each manifolded group of vessels, in order to permit controlled discharge inthe event of fire.
In case pressure vessels made from other materials are used, it shall be proven that the safety device willoperate before failure of the material due to high temperatures in case of fire.
10.2.3 Any pressure relief device shall be of a design such that:
when activated, it shall be able to keep the pressure not exceeding 1,1 times the maximum allowablepressure;
if it is adjustable, it can be sealed in the set position in order to prevent unauthorized adjustment;
it is marked with the set pressure and, where appropriate, the direction of flow.
10.3 Emergency isolation valve
An automatic emergency isolation valve shall be fitted on the outlet from any storage facility.
10.4 Pressure gauge
A pressure gauge shall be fitted to each storage unit.
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11 Station pipework and ancillary devices
11.1 Station pipework
Pipework and fittings shall be firmly and securely fixed to prevent disconnection in normal operation.
Components placed on different foundations, which can move separately, shall be connected by flexibleconnections.
11.2 Inlet pipework
In case of inlet pressures up to 16 bar, the inlet pipework should be in accordance with e.g. EN 12007-1, EN12007-2 or EN 12007-3.
11.3 Outlet pipework
The following applies to pipework downstream of the compressor(s):
11.3.1 General provisions
11.3.1.1 The outlet pipework should comply with applicable standards as e.g. the series of EN 13480-1,EN 13480-2, EN 13480-3, EN 13480-4, EN 13480-5 and EN 13480-6.
11.3.1.2 The number of joints shall be kept to a minimum.
11.3.1.3 Pipework shall be located in a position where it cannot be damaged by moving vehicles, orsuitable protection shall be provided.
11.3.1.4 Prior to a pneumatic or hydraulic test, welds shall be subjected to non destructive testing.
11.3.2 Above ground pipework
11.3.2.1 All above ground pipework shall be constructed of appropriate corrosion protected or stainlesssteel pipe.
11.3.2.2 Where overhead pipework crosses any vehicle access way it shall be so positioned and protectedto avoid damage from high vehicles.
11.3.2.3 Pipework shall be inspected on a regular basis according to local regulation
11.3.3 Underground pipework
11.3.3.1 Buried pipework inside the filling station should be avoided as far as possible. It is preferable thatpipework inside the filling station can be visually inspected.
11.3.3.2 All buried pipework joints shall be welded and the pipework shall be constructed of appropriatecarbon steel or stainless steel.
11.3.3.3 Buried pipework shall be inspected on a regular basis according to local regulations.
11.3.3.4 All buried pipework shall be protected against corrosion and subsequent damage. Carbon steelpipework shall be suitably protected by an anti-corrosion system. Stainless Steel pipework shall be buried insand.
11.3.3.5 Where the piping is cathodically protected or other considerations call for it, insulated connectionsshould be fitted to electrically isolate filling devices from gas pipes.
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11.3.3.6 Insulated connections installed above ground in hazardous areas should be provided withadequate distances to avoid sparking.
11.3.3.7 When installing insulated connections outside the covered area of the filling station the section ofunderground piping, including the insulation joint(s), shall be externally wrapped.
11.3.4 Pipework in ducts
11.3.4.1 The pipework may be installed in underground ducts with effective ventilation and drainage suchthat no explosive mixture will be present during normal operation.
11.3.4.2 The ducts shall be easily accessible for visual inspection of the pipework.
11.3.4.3 The construction and quality of the pipework shall be the same as for the above ground pipework.
11.3.4.4 Pipework shall be located in a duct or void only if the duct or void is adequately ventilated.
11.3.5 Flexible connections
Any flexible connection shall be suitable for the design parameters. For dispenser filling hose see 13.2.
11.4 Pressure gauges
11.4.1 All gauges shall have full scale reading no less than 1,2 times the ps.
11.4.2 All gauges throughout the filling station, storage facilities and dispenser shall have the same units.
11.5 Pressure testing
The complete installation shall be tested using an approved method. To do so, local regulations may beapplicable. If no such specific regulation exists, Annex F shall be applied.
11.6 Gas detection system
If a gas detection system is installed it shall comply with 14.1 of this standard, EN 61779-1 and EN 61779-2 .
12 Emergency shut down procedures
12.1 An emergency shut down procedure shall be provided to shut down the NGV filling station safely andisolate the gas inlet.
12.2 The procedure shall shut down the compressor and isolate the outlets of any storage by the operationof automatic valves. The isolation should be made as close to the filling point as possible by means of fail safeoperation of automatic valves.
For example, an emergency shut down procedure could be as follows:
a) the refuelling station power supply shall be isolated except power for the unit monitoring control and to the mechanicalventilation system;
b) the gas supply to the dispenser filling hose(s) shall be isolated;
c) the gas flow between the compressor, storage, and dispensing unit and also between storage sections shall bestopped. If more than one dispensing unit is connected to the storage, the delivery may be stopped with commonvalves.
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12.3 Emergency shutdown devices shall be suitably located throughout the filling station. Special attention tothis requirement shall be paid in case of self-service stations.
13 Dispenser
The location should be preferably in the open air and in a well ventilated position, but under certain conditionsin a room or building. In case of indoor refuelling a risk analysis shall be undertaken to assess the safety level.
13.1 Dispensing unit
13.1.1 Gas shall only be dispensed using equipment with the following safety devices:
break away system. The disconnection force of the break away device shall be lower than 500 N fordispensers for personal vehicles and 850 N for high flow dispensers for commercial vehicles in anydirection;
automatic shut off valve(s). It may be required by local regulation to install a minimum of two automaticshut-off valves in series.
13.1.2 The dispensing unit shall be protected against vehicle collision. In case of damage to the dispenserdespite the collision protector an automatic valve or excess flow valve shall be activated closing the supply tothe dispenser at its inlet.
13.1.3 When connected to the vehicle, the vehicle and dispensing equipment shall be equipotential. This isusually performed by a electrical conducting filling hose, complying to ISO 15500-17.
13.1.4 In case of public fast-fill self-service refuelling stations the dispensing unit shall be equipped with abutton or handle, such that the refuelling will only start when this button or handle is manually operated.
13.2 Filling hose
13.2.1 The filling hose shall be flexible and resistant to corrosion and mechanical damage. The hose shallcomply with the requirements of ISO 15500-17. It shall be supported adequately or coated to prevent kinkingand abrasion.
13.2.2 The hose shall be suitable for natural gas under normal operational conditions.
13.2.3 The length of the filling hose assembly should be the minimum required. It shall, however, not exceed5 metres.
13.2.4 The filling hose shall be safely stowed when not in use.
13.2.5 A suitable design standard for proof of adequate strength using a calculation method should beapplied.
13.2.6 The filling hose shall have a burst pressure (pb) of at least 4 times the maximum allowable pressure(pS).
NOTE: Until publication of this standard, no European or International standard for high pressure hoses and the testingthereof is known. Therefore suitable regulations as e.g. national standards may be applied until publication of suchEuropean or International standard.
13.2.7 The hose shall be marked with the maximum allowable pressure, the year of production and theproducer’ name and its identification mark.
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13.2.8 The hose connections shall stand a force in linear direction 20% greater than the force required tooperate the break-away device and the hose's burst pressure.
13.3 Filling nozzle
13.3.1 The filling nozzle shall be designed so that it only permits the flow of gas if there is an adequateconnection between the nozzle and the receptacle of the vehicle.
13.3.2 The nozzle shall comply with the requirements of ISO 14469 and shall match the receptacle of anyvehicle complying with ISO 15501-1:2000 and ISO 15501-2:2000.
13.3.3 When the filling nozzle is not in use, it shall be stored away to prevent moisture and debris fromentering.
13.4 Captive vent systems
In the interest of protection of the environment, consideration should be given to collecting the small volume ofgas released when the nozzle is removed from the vehicle filling point.
14 Electrical equipment and wiring
14.1 General
Where the equipment and wiring are placed in an hazardous area, they shall comply with the appropriatetypes of protection specified in EN 60079-14 standard, taking into account the zone of installation.
14.2 Earthing protection
Care must be taken to ensure that all metallic parts (for example framework, piping etc.) shall be adequatelybonded to a common earth.
14.3 Lightning protection
Measures for protection against lightning shall be considered to limit the overloading of cables and electricalequipment.
15 Testing, purging and commissioning
15.1 The equipment shall be visually inspected and mechanically tested (i.e. compressors, valves, etc). Thiscan be performed at the manufacturers’ site. All pressure loaded equipment shall be pressure and leak testedand adequately purged and commissioned. Upstream of the compression unit, consideration should be givento installing a start-up filter.
Documentation of this test shall be provided.
15.2 The compressor may need to be excluded from any testing and purging.
15.3 A pressure test shall be carried out as described in Annex F.
15.4 The system shall be purged using, for example, a method described in Annex G.
15.5 Proper operation of all safety equipment except safety valves shall be tested and documented.Documentation of this test shall be provided. Safety valves shall comply with EN ISO 4126-1. The integrity
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and documentation of primary safety devices shall be checked by reference to manufacturer's documentationand the existence of an anti-tampering system.
16 Marking, operating notices and instructions
16.1 General
All markings, signs and literature of a natural gas filling station shall be in the language(s) of the country whereit is intended to be installed.
16.2 Marking
A NGV filling station complying with the requirements of this standard and type approved by a notified bodymay be CE-marked by its manufacturer. In addition, the NGV filling station shall carry the following markingsin a durable, legible manner on a firmly attached data plate:
identification of the manufacturer and, where appropriate, identification of his authorized representativeestablished within the Community;
the year of manufacture;
unique identification of the station, such as type, series or batch identification and/or serial number;
essential limits such as maximum allowable pressures and temperature;
maximum delivery pressure;
nominal delivery pressure;
rated power in kW (Kilowatts) and supply voltage in V (Volts);
warning or special conditions for safe use.
16.3 Signs
The dispenser shall be clearly labelled, indicating that it dispenses natural gas or, if applicable, the type ofregenerative produced gas.
Signs shall be erected adjacent to the area which is classified as a hazardous area indicating that smoking,naked lights and the use of non-explosion protected electric equipment are prohibited.
16.4 Instruction signs
For self-service filling stations the filling instructions shall be displayed clearly at dispensing units immediatelyadjacent to each filling hose; for other filling stations the instructions shall be easily accessible for thepersonnel.
The instructions shall include the relevant safety precautions especially non-smoking, turn off engine. All signsshall comply with Council Directive 92/58/EEC.
Example instructions are detailed in Annex E (informative).
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16.5 Instructions
16.5.1 Instruction of employees
The refuelling attendant shall be well trained.
16.5.2 Installation and operating instruction
The installation and operating instructions shall be delivered with the station. They shall contain as a minimum
the recommendation to install an isolation valve between the gas distribution pipework and the fuellingstations inlet connection;
the mounting including assembling of different pieces of pressure equipment, if any;
how to put the station into service;
its proper operation;
the minimum requirements for maintenance including inspection by the operator as e.g. the visualinspection of the filling hose and nozzle;
the need to have the station periodically inspected in a way and frequency given by local regulation;
the need to replace the hose at least every ten years;
all information given in 16.1 except the serial number.
Where appropriate, technical documents, drawings and diagrams should be included for a full understandingof the instructions.
Where pipework is installed underground, the positioning and routing of the underground pipework shall berecorded in the instructions.
16.5.3 Potential hazard
All potential hazards shall be considered and included in the installation and operating instructions.Respective warning signs displayed accordingly (e.g. high pressure, high voltage).
16.5.4 Emergency plan
An emergency plan shall be set up for the natural gas refuelling station.
An example for an emergency plan procedure is given in D.3.
16.5.5 Cooling Effects
Consideration shall be given to the cooling effect which will occur when the system is depressurised.
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Annex A(informative) Examples: Hazardous areas
Figure A.1 — Hazardous area classification according to EN 60079-10
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A.1 Dispenser:
Links between upper and lower parts of the dispenser are gastight
Hypothesis:
ventilated (natural) ( at least 2 openings $100 cm² each)
Dispenser in open air
Safety shut off valve at the inlet closed when the dispenser is not operating
Valve opened only when filling a vehicle
Legend:
1 Non hazardous area
2 Hazardous area type 2
3 Valve closed
4 Valve open
r = 0,25 m around all openings
Figure A.2 — Hazardous areas (explosion protection zones) at CNG dispenser
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A.2 Storage and pressure vessels
Hypothesis:
Ventilated cover
Material of the cover gas proof
No venting of safety relief valve inside
Legend:
1 Non hazardous area(all around)
2 Hazardous area type 2
Figure A.3 — Hazardous areas at storage unit
Around the openings
without specific study orcalculation use r = 1 mwith using a grade of release of0,002 m3 / s and the codedeveloped by G. OOMS (seebibliography ) r = 0,25 m
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A.3 Compressors
Hypothesis:
Permanent ventilation (compressor running or not) natural or artificial
No venting of safety relief valve inside
Zone 2 inside and around the openings without specific study or calculation use r = 1 m by using a grade of release of 0,002 m3 / s andthe code developed by G. OOMS (see bibliography ) r =0.25 m
NHA around
A.4 Venting devices
Hypothesis:
NHA for small amounts of gas (such as the volume of gas released when the nozzle is removed from thereceptacle).
For other cases (venting of storage, pressure vessels, long pipes etc.):
Legend:
1: Hazardous area type 1
All dimensions given in m
Figure A.4 — Hazardous areas at ventilation openings
A.5 Pipework
Hypothesis:
Pipes (all) and welded fitting connections : NHA
Other fittings, valves, connections : ZONE 2 inside a sphere without specific study or calculation use r = 1 m with using a grade ofrelease of 0,02 m3 / s and the code developed by G. OOMS (see bibliography ) r = 0.25 m
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A.6 Vehicles
Hypothesis:
If they comply with national regulations and GRPE standards: NHA around vehicles
Venting volume of 120 normal m3 through a pipe of 55 mm internal diameter calculation made with the codedeveloped by G. OOMS (see bibliography)
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Annex B(informative) Safety distances
EQUIPMENT MINIMUM
REQUIREMENTS
Distance between CNG dispenser and other fueldispensers, should be determined according to therespective hazardous area requirements
STORAGE — OTHER FUELS STORAGE 5 m (*)
STORAGE — OTHER FUELS DISPENSER 5 m (**)
STORAGE — BUILDING OPENING 3 m (***)
COMPRESSOR — BUILDING OPENING 3 m (***)
Explanation
The above distances are based on the following considerations:
The extent of the hazardous area, which dictates the distance between possible leak sources at thestorage and dispenser and the property boundary and building openings, other sources of ignition shouldalso be controlled within this area.
The security of the equipment from collision of vehicles, due to the nature of the site this is a likely eventand the consequences of collision with the storage or compressor requires a safety distance.
The interactive consequences of the heat from ignited gas releases. The above table assumes a storedgas volume of up to 10.000 l water capacity at 250 bars. Special consideration should be given to largervolumes
The gas pressure blow regarded to safety distances.
(*) If the storage of the other fuel(s) is placed underground, the distance can be reduced to the respective hazard area. Thedistance may be reduced to some extent also by means of appropriate design or fire walls
(**) In case of the other fuel(s) dispenser the distance to the storage can be reduced to the respective hazardous areas bymeans of appropriate design or fire walls
(***) The distance can be reduced to the respective hazardous areas by means of appropriate design or fire walls
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Annex C(informative) Information on explosion protected equipment
The standard EN 1127-1 details the design and manufacture measures to achieve the required safety. It includesthe relationship between categories and zones and the applicable equipment in the different zones.
Information on the control and classification of hazardous places for gases and vapours by the use of ventilation isgiven in EN 60079-10. Equipment, used in hazardous area, shall be in accordance with the equipment categoriesas mentioned in EN 1127-1 and listed below.
Category 1G: Equipment for this category is intended for use in areas in which explosive atmospheres caused bymixtures of air and gases or mists are present continuously, for long periods or frequently.
NOTE: in general, this applies for zone 0 (see EN 60079-10).
Category 2G: Equipment of this category is intended for use in areas in which explosive atmospheres caused bygases, vapours or mists are likely to occur.
NOTE: in general, this applies for zone 1 (see EN 60079-10).
Category 3G: Equipment of this category is intended for use in areas in which explosive atmospheres caused bygases, vapours or mists are unlikely to occur or if they do occur, are likely to do so infrequently and for a shortperiod only.
NOTE: in general, this applies for zone 2 (see EN 60079-10).
Table D.1 — Type of protection allowed for electrical apparatus
Protection technique (Ex) Symbol Standard Zone
0 1 2
Intrinsic safety ia EN 60079-11 A A A
Intrinsic safety ib EN 60079-11 - A A
Flameproof d EN 60089-1 - A A
Increased safety e EN 60079-7 - A A
Oil immersion o EN 60079-6 - A A
Pressurised apparatus p EN 60079-2 - A A
Powder filling q EN 60079-5 - A A
Encapsulation ma EN 60079-18 A A A
Encapsulation mb EN 60079-18 - A A
Non sparking n EN 60079-15 - - AIntrinsically safe electricalsystems i EN 60079-25 A A A
General requirements forCategory 1 equipment – EN 60079-26 A A A
General requirements – EN 60079-0 A A A
A = allowedAny non-electrical equipment, intended for use in a potentially explosive atmosphere, shall comply with therequirements of EN 13463-1. To assess the category of the equipment it shall be subjected to an ignition hazardassessment in accordance with the applicable clauses of EN 13463-1.
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Annex D(informative) Instructions for filling
The following example details typical filling procedure instructions which shall be displayed in accordance withclause 16.
D.1 Filling procedure (for a typical fast-fill)
a) No smoking;
b) Turn off mobile phones and all electrical appliances;
c) Turn off engine;
d) Remove the dust plug from the vehicle filling connection;
e) Attach the filling hose to the fill point;
f) On completion of the fill, carefully disconnect the filling hose. A small escape of gas from the filling nozzlemay occur at this time;
g) Return the hose to the correct position on the dispenser,
h) Refit the dust plug/cap.
D.2 Filling procedure (for a typical slow-fill)
a) No smoking;
b) Turn off engine;
c) Remove the dust plug from the vehicle filling connection;
d) Attach the filling hose to the fill point;
e) Open the fuel valve on the fill post;
f) After the expected fill time has elapsed and the vehicle vessel(s) is/are full, close the fuel valve on the fillpost,
g) Carefully disconnect the filling hose. A small escape of gas from the filling nozzle may occur at this time;
h) Return the hose to the correct position on the fill post;
i) Refit the dust plug/cap.
D.3 Emergency plan instructions
Actions to carry out in case of fire or serious gas leakage of a refuelling station:
a) press the emergency shut down device (button)
b) extinguish all ignition sources, also in the buildings (pilot lights) and in the surrounding area.
c) turn off engines
d) notify the fire brigade, tel. 000-00000
e) notify the operator, name:......................, tel. 000-00000
f) notify people in the vicinity and direct them to a safe area.
g) do not use electrical switches
h) do not start engines.
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Annex E(normative) Hydrostatic and pneumatic testing
This annex provides an example of hydrostatic and pneumatic tests in accordance with directive 97/23/EC on thecomponents of the installation and the installation itself.
E.1 Testing
E.1.1 First inspection
Before a new refuelling station is commissioned for operation, it shall be tested. The test consists of at least:
Check for the completeness of test certificates of the components tested on the manufacturer’s premises withat least 1,43 times of their maximum allowable test pressure;
review of the construction, documentation, materials used and their implementation;
check of the hazardous area and electrical equipment used;
testing of strength at test pressure pt ; for this test, safety valves need to be blocked off;
testing for leakage at normal operation condition;
functional test including safety devices;
prevention of air entrainment into the parts of the system containing natural gas.
The function and adjustment of the safety devices can be demonstrated with a certificate by the manufacturer orthe supplier of the instruments.
A complete documentation, containing the proof of conformity to specification of the components, shall be preparedand handed over with the station.
A test report shall be prepared and handed over to the station operator.
E.2 Hydrostatic strength/pressure test of system components
This general strength/pressure test is intended to prove the strength of the system components and pipework, at1,43 times the maximum allowable pressure. This test may be either performed on site or at the premises of themanufacturer of the respective component.
E.2.1
Observe all relevant safety precautions outlined in Annex H.
E.2.2
In case that the gauges installed in the station could take damage from exceeding their design pressure, they shallbe isolated or replaced by gauges with suitable design pressure prior to the test.
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E.2.3
The system is filled with a suitable test liquid as e.g. glycol or liquid hydrocarbons. It may be necessary to providedrainage facilities, especially at low points in the system.
E.2.4
Increase the test pressure gradually, in increments of 10 % of the maximum test pressure, to 1,43 times themaximum allowable pressure then stop the pressurizing pump. During this period, plot the pressure reading againsttime elapsed.
E.2.5
On reaching the test pressure, continue to plot pressure against time elapsed for a minimum of 1 h, recording anypressure variation. The pressure shall never exceed 5 % above the nominal test pressure.
E.2.6
A satisfactory strength test, to be proved by the subsequent pneumatic test, is indicated by the lack of a suddendrop in pressure.
E.2.7
Completely empty the system components of the test liquid (see E.2.3), using a procedure issued by the installer ofthe equipment.
NOTE: Instead of a hydrostatic test a pneumatic test may be applied when safety for any person in the area (personnel andgeneral public) is provided. Pneumatic test are usually chosen for onsite testing.
E.3 Pneumatic leak test of the complete system
E.3.1
After successful completion of any hydrostatic strength/pressure test and following the complete refitting ofseparately tested small bore pipework together with other equipment, subject the completed system to a pneumaticleak test.
E.3.2
Observe all safety precautions outlined in informative annex H.
E.3.3
Subject the completed pipework system to an initial leak test at a pressure of 2 bar.
E.3.4
Pressurize the installation slowly up to the maximum allowable pressure of the system and hold for a periodadequate to ensure that the installation can be thoroughly inspected.
E.3.5
Check all joints, flanges and glands on valves, pipework and fittings, for leaks, using an appropriate leak detectionfluid. Correct any leak detected then repeat the test procedure.
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Annex F(informative) Subsequent testing after commissioning
Any testing after commissioning be it periodically or after substantial changes to the NGV filling station, is subject tonational or local regulation.
F.1 Obligation of registration and periodic inspections
Where it is stipulated in these requirements that the person operating the installation is obliged to carry out or havecarried out measurements, inspections or check-ups, the results should be stored and kept available for authorisedinspection officers at least until the results of the next measurement, inspection or check-up are available, unless itis stated otherwise in the applicable national or local regulations.
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Annex G(informative) Safety precautions for hydrostaticand pneumatic testing
G.1 Safety precautions
G.1.1
The safety of all persons, whether or not involved in the testing, is of paramount importance. Do not carry out anyprocedure which would violate this concept. All personnel engaged in testing will need to be instructed fullyregarding the possible hazards involved in the testing, particular attention being paid to securing pipes to preventwhip following any failure.
G.1.2
Consult at the pipework design stage with the designer on the adequacy of the safety precautions proposed by thecontractor. The safety precautions will need to ensure that, as far as possible, no person is exposed to injuryshould any part of the pipework system fail during the test operation. The safety precautions will need to be subjectto the written approval of the engineer before the test, with particular reference to the following:
adequacy of protection of adjacent pipework and equipment;
adequacy of the pressure gauges installed in the station;
extent of the area cleared for test safety purposes;
adequacy of any applicable non-destructive testing carried out before the test including testing carried outpreviously by others;
resistance of the materials to fast fracture;
procedure to prevent local chilling during filling and emptying;
external of remote monitoring provided during test.
G.1.3
Take precautions to protect any adjacent pipework or equipment from the effects of failure of the pipework.
G.1.4
For hydrostatic testing, if test water becomes contaminated by the test, disposal arrangements shall be made.
G.1.5
Define a test area and agree it with the engineer. This test area will include all enclosed areas through which thepipework runs and local access ways. The boundaries of the test area shall be defined by marker tapes. Displayproper warning notices reading "WARNING - STATION UNDER TEST" at all points where access may be gainedto the test area.
G.1.6
Attention is drawn to the fact that if a test medium, such as compressed nitrogen, is reduced to the test pressurefrom high pressure storage, its temperature will fall. The test arrangements will need to be such that the
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temperature of the medium entering the pipework under test is not lower than the agreed test temperature. In orderto prevent condensation within the pipework, do not allow the temperature of the test medium to fall below the dewpoint at the corresponding test pressure.
G.2 Special Drying
After completion of the test special drying may be required. In which case dry the system by passing a largequantity of dry air or nitrogen, with a dew point below -40 C, through the system until the dew point of the exit gasis -40 C. At this stage, leave the inlet and outlet of the pipework to stand to allow the dry gas to absorb any smallresidual pockets of water, and then carry out a further dew point check which, for acceptance, will need to be -40C or less at normal conditions.
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Annex H(informative) Purging
This annex is an example of the implementation of purging procedures.
H.1 General provisions
Consideration should be given to the environmental impact of natural gas in the atmosphere.
H.2 Safety precautions
H.2.1
Do not commence purging without a full knowledge of the pipework and ancillary equipment.
H.2.2
Purge primary gas meters under the supervision of a competent person nominated by the gas supplier.
H.2.3
In all the purge operations, even the simplest one, prepare and follow a written procedure appropriate to theinstallation.
H.2.4
Take precautions to reduce, as far as practical, the possible hazards arising from venting, for example by avoidingventing close to property or potential sources of ignition such as electrical plant and equipment. Warning notices, inparticular "No Smoking" and "No Naked Lights", will need to be displayed prominently around the area wherepurging is to take place. Do not work on any section of the plant undergoing purging.
H.2.5
Make available fire extinguishers on the site during the purging operation.
H.2.6
Carry out purging continuously. If there is any discontinuity, abandon the purge and repeat the complete operation.
H.2.7
When conducting an inert gas or air purge, take precautions to prevent the purge gases from entering the gassuppliers' gas distribution network.
H.3 Procedures
H.3.1
Following a satisfactory pressure test, lower the pressure in the pipework to be purged to a level to admit safely thepurge gas to meet the criteria of the purge.
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H.3.2
Purging from gas to air or air to gas can be carried out providing a minimum velocity within all the associatedpipework and equipment can be maintained to avoid mixing
H.3.3
If the velocity stated above cannot be maintained, then consider purging via an inert gas route. The inert gas wouldbe nitrogen.
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Annex I(informative) Example of filling plan with three bank system andtwo dispenser units
Legend:
1 Gas supply system 6 Safety valve 12 Pressure control valve
2 Dryer 7 Compressor 13 Dispenser
3 Meter 8 Liquid separator 14 Filling nozzle
4 Isolating valve 9 Control system 15 Expansion Vessel (optional)
5 Non return valve 10/11/17 Storage 16 Compressor (optional)
18 Pressure indicator 19 Emergency gas isolating valve (to be added)
Figure I.1 — Schematic of a CNG filling station with three bank storage unit and two dispenser units
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Annex J(informative) Refuelling station – Informative diagram
Figure J.1 — Refuelling station – Informative diagram
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Annex K (informative) Reference standards applied for materials in theconstruction of CNG filling stations according to 6.1.1 not being CEN or
ISO standards
DIN 30690-1 (1999) Construction elements in the gas supply system – Part 1: Requirements forconstruction elements in gas supply systems
AD-Merkblatt W 0 (1986) General principles for materials
AD-Merkblatt W 4 (1992) Tubes made from non-alloyed and alloy steel
AD-Merkblatt W 10 (1987) Materials for low temperatures - Ferrous materials
AD-Merkblatt W 12 (1988) Seamless hollow components made from non-alloyed and alloy steels forpressure vessel shells
AD-Merkblatt B 0 (1995) Design of pressure vessels
AD-Merkblatt B 1 (1986) Cylindrical and spherical shells subjected to internal overpressure
AD-Merkblatt B 3 (1990) Domed ends subject to internal or external pressure
AD-Merkblatt B 9 (1995) Openings in cylindrical, conical and spherical shells
AD-Merkblatt S 1 (1998) Simplified analysis for cyclic loading
VdTÜV-Werkstoffblatt 228 (1984) Rolled and forged steel 27 CrMo 4 I, II and III
VdTÜV-Werkstoffblatt 431 (2002) Fortified Cr-Mo-alloy rolled and forged steel 34 CrMo 4 and 34 CrMo 4/A -Material-Nr. 1.7220
2004 ASME Boiler and Pressure Vessel Code - Section II - Part A - SA-372/SA-372M Specification for carbonand alloy steel forging
ASTM A 105 Standard Specification for Carbon Steel Forgings for Piping Applications
ASTM A 106 Standard Specification for Seamless Carbon Steel Pipe for High-TemperatureService
ASTM A 108 Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished
ASTM A 179/A Standard Specification for Seamless Cold-Drawn Low-Carbon Steel Heat-Exchanger and Condenser Tubes
ASTM A 182/A Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forgedfittings, and Valves and Parts for High-Temperature Service
ASTM A 193/A Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials forHigh-Temperature Service
ASTM A 194/A Standard Specification for Carbon and Alloy Steel Nuts for Bolts for HighPressure or High Temperature Service, or Both
ASTM A 234/A Standard Specification for Piping Fittings of Wrought Carbon Steel and AlloySteel for Moderate and High Temperature Service
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ASTM A 262/A Standard Practices for Detecting Susceptibility to Intergranular Attack inAustenitic Stainless Steel
ASTM A 269 Standard Specification for Seamless and Welded Austenitic Stainless SteelTubing for General Service
ASTM A 312/A Standard Specification for Seamless, Welded, and Heavily Cold WorkedAustenitic Stainless Steel Pipes
ASTM A 333/A Standard Specification for Seamless and Welded Steel Pipe for Low-Temperature Service
ASTM A 334/A Standard Specification for Seamless and Welded Carbon and Alloy-Steel Tubesfor Low-Temperature Service
ASTM A 350 Standard Specification for Carbon and Low-Alloy Steel Forgings, Requiring NotchToughness Testing for Piping Components
STM A 403/A Standard Specification for Wrought Austenitic Stainless Steel Pipe Fittings
ASTM A 516/A Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate-and Lower-Temperature Service
ASTM A 576-90b Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality
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Bibliography
ADR Act on the European Agreement on the Transportation of Dangerous Goods by Road(ADR)
89/336/EEC Council directive of 3 May 1989 on the approximation of the laws of the memberstates relating to electromagnetic compatibility
98/37/EC Directive 98/37/EC of the European Parliament and of the Council of 22 June 1998 onthe approximation of the laws of the member states relating to machinery
92/58/EEC Council Directive 92/58/EEC of 24 June 1992 on the minimum requirements for theprovision of safety and/or health signs at work
94/9/EC Directive 94/9/EC of the European Parliament and of the Council of 23 March 1994 onthe approximation of the laws of the Member States concerning equipment andprotective systems intended for use in potentially explosive atmospheres
97/23/EC Directive 97/23/EC of the European Parliament and of the Council of 29 May 1997 onthe approximation of the laws of the Member States concerning pressure equipment
EN ISO 12100-1 Safety of machinery - Basic concepts, general principles for design - Part 1: Basicterminology, methodology
ISO 10101-1 Natural gas – Determination of water by the Karl Fisher method – Part 1: Introduction
ISO 10101-2 Natural gas – Determination of water by the Karl Fisher method – Part 2: Titrationprocedure
ISO 10101-3 Natural gas – Determination of water by the Karl Fisher method – Part 3: Coulometricprocedure
G.OOMS A new method for the calculation of the plume path of gases emitted by a stack(KSLA) Atmospheric Environment, Pergamon Press 1972, Vol. 6, pp. 899-909
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Annex ZA(informative)
Clauses of this European Standard addressing essential requirements orother provisions of EU Directives.
This European Standard has been prepared under a mandate given to CEN by the European Commission toprovide a means of conforming to Essential Requirements of the New Approach Directive 97/23/EC.
Once this standard is cited in the Official Journal of the European Communities under that Directive and hasbeen implemented as a national standard in at least one Member State, compliance with the clauses of thisstandard given in table ZA confers, within the limits of the scope of this standard, a presumption of conformitywith the corresponding Essential Requirements of that Directive and associated EFTA regulations.
Table ZA — Correspondence between this European Standard and Directive 97/23/EC
Essentialrequirement
Object Clauses in the standardwhich comply wholly orpartly with the essential
safety requirements
2.2 Adequate strength 6.1
2.2.2 Design for adequate strength 6.1.2, 10.1.1, 11.3.1.1
2.3 Safe handling and operation 6.1, 9.4, 13.1.1, 16.4
2.4 Means of examination 11.5
2.5 Means of draining and venting 6.1, 9.3
2.6 Corrosion or other chemical attack 6.1.1, 11.3.2.1; 11.3.3.4, 13.2.1
2.7 Wear 16.5.2
2.8 Assemblies 6.1.2, 13.2.3
2.9 Provisions for filling and discharge 6.3.1, 6.3.2, 6.4, 8.1.1; 13.1.3;13.1.4; 13.3.1; 13.3.2
2.10 Protection against exceeding the allowablelimits of pressure equipment
6.3.1, .6.3.2, 9.4.1, 9.4.2,10.2.1, 11.4.1
2.11.1 Safety accessories 6.3.1, 6.3.2, 9.4.1, 9.4.2, 10.2.1
2.11.2 Pressure limiting devices 6.3.1, 9.4.1, 9.4.2, 10.2.1
2.11.3 Temperature monitoring devices 9.4.1
2.12 External fire 10.2.2
3.1.2 Permanent joining 6.1.4
3.1.3 Non-destructive tests 6.1.4
3.1.5 Traceability 5.1
3.2 Final assessment 15.3
3.2.1 Final inspection 15.1, D.1.1
3.2.2 Proof test 15.3, D.3, Annex E
3.2.3 Inspection of safety devices D.1.1
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Table ZA (continued)
Essentialrequirement
Object Clauses in the standardwhich comply wholly orpartly with the essentialsafety requirements
3.3 Marking and labelling 16.1; 16.2
3.4 Operating instructions 16.5.2; 16.5.3
4 Materials 6.1.1
4.1 Materials for pressurized parts 6.1.1
4.2 (untitled) 6.1.1
6 a 11.1; 11.3.3.4; 11.3.3.7
6 b 9.3
6 d 6.1.2, 9.1.3, 9.1.4
6 e 13.1.1, 13.3.1
6 g 16.5.2