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CEN/TC 326 Date: 2007-07

prEN 13638:2007 CEN/TC 326 Secretariat: DIN

NGV filling stations Tankstellen fĂźr mit Erdgas betriebene Fahrzeuge (NGV) Stations service pour vĂŠhicules fonctionnant au gaz naturel (GNV)

ICS: Descriptors:

Document type: European Standard Document subtype: Document stage: Formal Vote Document language: E C:\Dokumente und Einstellungen\klaas\Lokale Files\OLKB\EN_13638_(E)_070709.doc STD Version 2.2

Einstellungen\Temporary

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prEN 13638:2007 (E)

Contents

Page

Foreword..............................................................................................................................................................6 Introduction ............................................................................................................................................6 1

Scope ......................................................................................................................................................7

2

Normative References ...........................................................................................................................8

3

Definitions ............................................................................................................................................12

4

Symbols and Abbreviations ...............................................................................................................16

5 5.1 5.2 5.3 5.4 5.5 5.5.1 5.5.2 5.5.3 5.6 5.7 5.8

General provisions ..............................................................................................................................16 General..................................................................................................................................................16 Gas compressor...................................................................................................................................16 Gas storage ..........................................................................................................................................17 Mother daughter station......................................................................................................................17 Dispenser..............................................................................................................................................17 Components .........................................................................................................................................17 Filling methods ....................................................................................................................................17 Operation ..............................................................................................................................................17 Control systems...................................................................................................................................18 Dryer......................................................................................................................................................18 Gas cooling system .............................................................................................................................18

6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.1.9 6.1.10 6.1.11 6.1.12 6.1.13 6.1.14 6.1.15 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.3 6.4 6.5

General principles of design and installation...................................................................................18 General construction...........................................................................................................................18 Materials ...............................................................................................................................................18 Prerequisites for the various elements of the assembly.................................................................19 Optional components ..........................................................................................................................19 Permanent joining of components.....................................................................................................19 Working area ........................................................................................................................................20 Noise attenuation.................................................................................................................................20 Collision protection .............................................................................................................................20 Traffic management.............................................................................................................................20 Foundation ...........................................................................................................................................20 Unauthorized access ...........................................................................................................................20 Requirements for the location of components.................................................................................20 Explosion protection measures .........................................................................................................20 Building regulations ............................................................................................................................21 Fire ........................................................................................................................................................21 Routine isolation..................................................................................................................................21 Gas composition..................................................................................................................................21 General..................................................................................................................................................21 Gas supplied to the filling station ......................................................................................................21 Gas supplied to the dispenser ...........................................................................................................21 Gas Composition during maintenance..............................................................................................21 Safety devices ......................................................................................................................................21 General..................................................................................................................................................21 Maximum allowed delivery pressure .................................................................................................22 Auxiliary safety devices ......................................................................................................................22 Delivery pressure and temperature to the vehicles .........................................................................22 Venting ..................................................................................................................................................22

7 7.1

Location and layout of equipment .....................................................................................................23 General provisions ..............................................................................................................................23

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7.1.1 7.1.2 7.2 7.3 7.4 7.5 7.5.1 7.6 7.7 7.7.1

Location................................................................................................................................................23 Fire fighting ..........................................................................................................................................23 Hazardous areas..................................................................................................................................23 Storage Facility (including ancillary equipment) .............................................................................23 Dispenser .............................................................................................................................................23 Enclosures ...........................................................................................................................................24 General Provisions..............................................................................................................................24 Canopies...............................................................................................................................................24 Restrictions and safety distances .....................................................................................................24 General Provisions..............................................................................................................................24

8 8.1 8.1.1 8.1.2 8.1.3 8.1.4

Gas supply, metering and composition ............................................................................................24 General Provisions..............................................................................................................................24 Connection to the gas supply ............................................................................................................24 Non-return system...............................................................................................................................24 Low inlet pressure...............................................................................................................................24 Special equipment...............................................................................................................................25

9 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.2 9.2.1 9.3 9.4 9.4.1 9.4.2 9.5 9.6 9.6.1 9.7 9.8 9.9 9.9.1 9.9.2 9.9.3 9.9.4

Gas compressor (including ancillaries) ............................................................................................25 General Provisions..............................................................................................................................25 Gas supplied from the compressor...................................................................................................25 Design...................................................................................................................................................25 Vibration ...............................................................................................................................................25 Pulsation...............................................................................................................................................25 Protection against weather.................................................................................................................25 Accessibility.........................................................................................................................................25 Gas recovery........................................................................................................................................25 General provisions ..............................................................................................................................25 Condensate drainage and disposal...................................................................................................25 Stage safety devices ...........................................................................................................................26 General provisions ..............................................................................................................................26 Relief Valve ..........................................................................................................................................26 Delivery line non-return valve ............................................................................................................26 Suction line components....................................................................................................................26 General provisions ..............................................................................................................................26 Instrumentation ...................................................................................................................................26 Markings ...............................................................................................................................................27 Instructions ..........................................................................................................................................27 General .................................................................................................................................................27 Operation instructions ........................................................................................................................28 Servicing instruction...........................................................................................................................30 List of parts required for servicing ....................................................................................................31

10 10.1 10.2 10.3 10.4

Storage facility (including ancillaries)...............................................................................................31 Storage pressure vessels ...................................................................................................................31 Pressure relief devices .......................................................................................................................31 Emergency isolation valve .................................................................................................................31 Pressure gauge....................................................................................................................................31

11 11.1 11.2 11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.4 11.5 11.6

Station pipework and ancillary devices ............................................................................................32 Station pipework..................................................................................................................................32 Inlet pipework ......................................................................................................................................32 Outlet pipework ...................................................................................................................................32 General provisions ..............................................................................................................................32 Above ground pipework .....................................................................................................................32 Underground pipework .......................................................................................................................32 Pipework in ducts................................................................................................................................33 Flexible connections ...........................................................................................................................33 Pressure gauges..................................................................................................................................33 Pressure testing ..................................................................................................................................33 Gas detection system .........................................................................................................................33

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12

Emergency shut down procedures....................................................................................................33

13 13.1 13.2 13.3 13.4

Dispenser..............................................................................................................................................34 Dispensing unit ....................................................................................................................................34 Filling hose ...........................................................................................................................................34 Filling nozzle ........................................................................................................................................35 Captive vent systems ..........................................................................................................................35

14 14.1 14.2 14.3

Electrical equipment and wiring.........................................................................................................35 General..................................................................................................................................................35 Earthing protection..............................................................................................................................35 Lightning protection ............................................................................................................................35

15

Testing, purging and commissioning................................................................................................35

16 16.1 16.2 16.3 16.4 16.5 16.5.1 16.5.2 16.5.3 16.5.4 16.5.5

Marking, operating notices and instructions....................................................................................36 General..................................................................................................................................................36 Marking .................................................................................................................................................36 Signs .....................................................................................................................................................36 Instruction signs ..................................................................................................................................36 Instructions ..........................................................................................................................................37 Instruction of employees ....................................................................................................................37 Installation and operating instruction ...............................................................................................37 Potential hazard ...................................................................................................................................37 Emergency plan ...................................................................................................................................37 Cooling Effects.....................................................................................................................................37

Annex A (informative) Examples: Hazardous areas .....................................................................................38 A.1 Dispenser: ............................................................................................................................................39 A.2 Storage and pressure vessels............................................................................................................40 A.3 Compressors........................................................................................................................................41 A.4 Venting devices....................................................................................................................................41 A.5 Pipework ...............................................................................................................................................41 A.6 Vehicles ................................................................................................................................................42 Annex B (informative) Safety distances .........................................................................................................43 Annex C (informative) Information on explosion protected equipment .....................................................44 Annex D (informative) Instructions for filling ................................................................................................45 D.1 Filling procedure (for a typical fast-fill) .............................................................................................45 D.2 Filling procedure (for a typical slow-fill) ...........................................................................................45 D.3 Emergency plan instructions .............................................................................................................45 Annex E (normative) Hydrostatic and pneumatic testing.............................................................................46 E.1 Testing ..................................................................................................................................................46 E.1.1 First inspection ....................................................................................................................................46 E.2 Hydrostatic strength/pressure test of system components ...........................................................46 E.2.1 ...............................................................................................................................................................46 E.2.2 ...............................................................................................................................................................46 E.2.3 ...............................................................................................................................................................47 E.2.4 ...............................................................................................................................................................47 E.2.5 ...............................................................................................................................................................47 E.2.6 ...............................................................................................................................................................47 E.2.7 ...............................................................................................................................................................47 E.3 Pneumatic leak test of the complete system ....................................................................................47 E.3.1 ...............................................................................................................................................................47 E.3.2 ...............................................................................................................................................................47 E.3.3 ...............................................................................................................................................................47 E.3.4 ...............................................................................................................................................................47 E.3.5 ...............................................................................................................................................................47 Annex F (informative) Subsequent testing after commissioning ................................................................48 F.1 Obligation of registration and periodic inspections ........................................................................48

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Annex G (informative) Safety precautions for hydrostatic and pneumatic testing.......49 G.1 Safety precautions ..............................................................................................................................49 G.1.1 ...............................................................................................................................................................49 G.1.2 ...............................................................................................................................................................49 G.1.3 ...............................................................................................................................................................49 G.1.4 ...............................................................................................................................................................49 G.1.5 ...............................................................................................................................................................49 G.1.6 ...............................................................................................................................................................49 G.2 Special Drying......................................................................................................................................50 Annex H (informative) Purging........................................................................................................................51 H.1 General provisions ..............................................................................................................................51 H.2 Safety precautions ..............................................................................................................................51 H.2.1 ...............................................................................................................................................................51 H.2.2 ...............................................................................................................................................................51 H.2.3 ...............................................................................................................................................................51 H.2.4 ...............................................................................................................................................................51 H.2.5 ...............................................................................................................................................................51 H.2.6 ...............................................................................................................................................................51 H.2.7 ...............................................................................................................................................................51 H.3 Procedures ...........................................................................................................................................51 H.3.1 ...............................................................................................................................................................51 H.3.2 ...............................................................................................................................................................52 H.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 CNG filling 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 or other 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 for natural 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 the European 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 this document.

Introduction

This standard provides requirements for the design, manufacturing, assembling, installation and testing 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 and assemblies for compressed Natural Gas (CNG) vehicle filling stations filling natural gas vehicle tanks up to the nominal delivery pressure of 200 bar at 15C. It may be applicable for higher delivery pressures, having due regard to the safety of operation of components, safety distances, mechanical strength and soundness testing of the installation. 1.2 It applies to filling stations supplied with normally distributed Natural Gas as defined in EN ISO 14532. It will be appropriate for other fuel gases, including those generated from landfill sites. However, the different constituent characteristics shall be recognised, in particular their possible consequent effect upon materials and 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/joint separating internal piping from the pipeline network, see Annex J). The filling station nozzles are considered as 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 of this 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 Informative Annex 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 listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated reference, the latest 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 - General principles

EN 682 (2002)

Elastomeric seals - Materials requirements for seals used in pipes and fittings carrying gas 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 and methodology.

EN 1964-1 (1999)

Transportable gas cylinders - Specification for the design and construction of refillable transportable seamless steel gas cylinders of water capacities from 0, 5 litre up to and including 150 litres - Part 1: Cylinders made of seamless steel with an R<(Index)m> value of less than 1100 Mpa

EN 1964-2 (2001)

Transportable gas cylinders - Specification for the design and construction of refillable transportable seamless steel gas cylinders of water capacities from 0, 5 litre up to and including 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 nonalloy structural steels

EN 10025-3 (2004)

Hot rolled products of structural steels - Part 3: Technical delivery conditions for normalized/normalized rolled weldable fine grain structural steels

EN 10025-4 (2004)

Hot rolled products of structural steels - Part 4: Technical delivery conditions for thermomechanical rolled weldable fine grain structural steels

EN 10025-5 (2004)

Hot rolled products of structural steels - Part 5: Technical delivery conditions for structural steels with improved atmospheric corrosion resistance

EN 10025-6 (2004)

Hot rolled products of structural steels - Part 6: Technical delivery conditions for flat products of high yield strength structural steels in the quenched and tempered condition

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 steels with specified elevated temperature properties

EN 10028-3 (2003)

Flat products made of steels for pressure purposes - Part 3: Weldable fine grain steels, normalized

EN 10028-4 (2003)

Flat products made of steels for pressure purposes - Part 4: Nickel alloyed steels with specified low temperature properties

EN 10028-5 (2003)

Flat products made of steels for pressure purposes - Part 5: Weldable fine grain steels, thermomechanically rolled

EN 10028-6 (2003)

Flat products made of steels for pressure purposes - Part 6: Weldable fine grain steels, 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 special steels

EN 10083-2 (1996)

Quenched and tempered steels - Part 2: Technical delivery conditions for unalloyed quality 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, hotrolled 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 of corrosion 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 general purposes

EN 10204 (2000)

Metallic products â&#x20AC;&#x201C; 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 unit length

EN 10222-1 (2002)

Steel forgings for pressure purposes - Part 1: General requirements for open die forgings

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EN 10222-3 (1999)

Steel forgings for pressure purposes - Part 3: Nickel steels with specified low temperature properties

EN 10222-4 (2001)

Steel forgings for pressure purposes - Part 4: Weldable fine grain steels with high proof strength

EN 10222-5 (1999)

Steel forgings for pressure purposes - Part 5: Martensitic, austenitic and austeniticferritic 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 general engineering 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 and tempering

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 including 16 bar - Part 1: General functional recommendations

EN 12007-2 (2000)

Gas supply systems - Pipelines for maximum operating pressure up to and including 16 bar - Part 2: Specific functional recommendations for polyethylene (MOP up to and including 10 bar)

EN 12007-3 (2000)

Gas supply systems - Pipelines for maximum operating pressure up to and including 16 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 method and 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: General requirements

EN 60079-1 (2004)

Electrical apparatus for potentially explosive atmospheres – Part 1: Flameproof enclosures “d”

EN 60079-7 (2003) “e”

Electrical apparatus for potentially explosive atmospheres – Part 7: Increased safety

EN 60079-10 (2003)

Electrical apparatus for explosive gas atmospheres – Part 10: Classification of hazardous 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 in hazardous 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 and maintenance of electrical installations in hazardous areas (other than mines)

EN 60079-18 (2004)

Electrical apparatus for explosive gas atmospheres - Part 18: Construction, test and marking of type of protection encapsulation "m" electrical apparatus

EN 60079-19 (2002)

Electrical apparatus for explosive gas atmospheres - Part 19: Repair and overhaul for apparatus used in explosive atmospheres (other than mines or explosives)

EN 60079-26 (2004) Electrical apparatus for potentially explosive atmospheres – Part 26: Construction, test and marking of Group II Zone 0 electrical apparatus CLC/TR EN 50054 (2003) Electrostatics - Code of practice for the avoidance of hazards due to static electricity 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° compression fittings 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 seal fittings EN ISO 8434-4 (2000) Metallic tube connections for fluid power and general use - Part 4: 24° cone connectors with O- ring weld-on nipples EN ISO 11120 (1999)

Gas cylinders - Refillable seamless steel tubes water capacity between 150 l and 3000 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 fuel for vehicles prEN ISO 15609-1 (2000) Specification and approval of welding procedures for metallic materials - Welding procedure 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-hardening unalloyed and low alloyed wrought steel in form of different black products

ISO 9809-1 (1999)

Gas cylinders - Refillable seamless steel gas cylinders - Design, construction and testing - Part 1: Quenched and tempered steel cylinders with tensile strength less than 1100 MPa

ISO 9809-2 (2000)

Gas cylinders; Refillable seamless steel gas cylinders - Design, construction and testing - Part 2: Quenched and tempered steel cylinders with tensile strength greater than or equal to 1100 MPa

ISO 9809-3 (2000)

Gas cylinders - Refillable seamless steel gas cylinders; Design, construction and testing - 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: Safety requirements

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: 3.1 assembly sub-system of CNG filling stations comprising several components, e.g. a container with the compressor and storage unit 3.2 building structure that cannot be defined as an open building 3.3 burst pressure (pb) pressure which causes failure and consequential fluid loss through the component envelope 3.4 break-away device device which, when activated, stops gas flow from the dispenser (for example if the vehicle moves away) while still connected to the refuelling hose 3.5 canopy a roof, for example a shelter, a hood etc., which affords a degree of weather protection

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3.6 cascade dispensing sequence means of allowing efficient use of the gas storage facility by dividing it into banks operating at different pressure levels 3.7 competent person person having the ability, appropriate training, knowledge and experience, to supervise or carry out the work being undertaken in a safe and proper manner 3.8 compression unit unit that compresses the natural gas consisting of one or more compressors, including all piping and equipment 3.9 compressor machine which increases the pressure of gas from a low to a higher level 3.10 cylinder any vessel used for the storage of compressed natural gas 3.11 blow down vessel vessel which receives compressed gas from the high pressure section of the installation and conducts it to the input of the compression system. Also serves to collect the eliminated liquids 3.12 dispenser the equipment through which the compressed natural gas is supplied to the vehicle 3.13 dryer system which decreases the water content of natural gas 3.14 enclosure designated structure, not a building, but which may be a housing, a room, a container etc., which encloses a component of the station 3.15 explosive gas atmosphere mixture with air, of a flammable material in the form of gas or vapour in which, after ignition, combustion spreads throughout the unconsumed mixture 3.16 fast fill filling operation which is comparable in duration to that of liquid fuel 3.17 filling station location at which gas is dispensed into a vehicle storage pressure vessel 3.18 fire wall wall, screen or separating partition erected in the open air to reduce the effects from radiated heat and to ensure an adequate dispersion distance for Natural Gas leaking from any vessel

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3.19 gas conditioning equipment equipment to filter and/or remove unwanted constituents (moisture, debris, liquid and vapours) from gas either prior to or after compression 3.20 hazardous area area in which an explosive gas atmosphere is present, or may be expected to be present, in quantities such as to require special precautions for the construction, installation and use of apparatus 3.21 liquid separator device which causes any liquids within the gas to drop out of suspension for collection. A liquid separator can be placed after compression of the natural gas 3.22 lower explosive limit (LEL) the concentration of flammable gas or vapour in air below which the gas atmosphere is not explosive. For natural gas containing only methane the LEL is 5.5 % by volume. For example 10 % LEL means 0.55 % gas in air 3.23 maximum allowable pressure ( pS) maximum pressure for which the system is designed, as specified by the manufacturer 3.24 overpressure pressure above the maximum allowable pressure which shall be prevented by safety devices 3.25 delivery pressure pressure at which the gas is delivered to the vehicle 3.26 nominal delivery pressure pressure at which filling automatically stops 3.27 maximum delivery pressure maximum pressure acceptable by the vehicle to be filled 3.28 mobile storage multi-cylinder or tank fixture permanently mounted on a special vehicle and used for the transportation of natural gas to other refuelling stations (see mother -daughter) 3.29 mother-daughter a station not connected to the pipeline (daughter) where gas is supplied by road transport from a station connected to the pipeline (mother). The transport arrangements are regulated by the ADR Directive (see mobile storage) 3.30 natural gas a 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 carbon dioxide, plus trace constituents

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3.31 normal operation situation when the equipment is operating within its design parameters 3.32 non-hazardous area area in which an explosive gas is not expected to be present in quantities such as to require special precautions for the construction, installation and use of apparatus 3.33 open building construction, in which the same ventilation conditions are present as in the open air and no obstruction for natural air circulation is present 3.34 on site filling filling where many vehicles are connected at the same time for several hours 3.35 primary grade of release release of gas which is likely to occur under normal operation 3.36 recovery vessel vessel that recovers gas from the compressor and its ancillaries and which may also serve to damp out pressure pulsations in the compressor inlet 3.37 safety distance distance between the filling station, its components and structures and other installations and structures in the vicinity. This distance reduces the degree of danger in the case of an incident 3.38 secondary grade release release of gas which is unlikely to occur in normal operation and will have only a limited duration 3.39 slow fill filling operation which takes, typically, several hours 3.40 storage any number of suitable compressed natural gas storage containers designed for the purpose of containing and subsequently releasing compressed natural gas 3.41 test pressure (pt) pressure to which the installation or part of installation, is tested. Different levels may be required for storage pressure vessels and other components 3.42 ventilation movement of air and its replacement with fresh air due to the effects of wind, temperature gradients, or artificial means (for example fans or extractors)

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3.43 vehicle refuelling appliance(VRA) 3 natural gas compressor package not containing storage , having a flow rate not exceeding 20 m /hr (stp) at 3 standard conditions with a max. gas outlet pressure of 260 bar and with a max. gas containment 0.5 sm (stp) and intended for unattended refuelling of vehicles, having a properly installed containment system 3.44 zones hazardous areas are classified into zones based upon the frequency of the occurrence and duration of an explosive gas atmosphere 3.44.1 zone 0 area in which an explosive gas atmosphere is present continuously or for long periods 3.44.2 zone 1 area in

which

an

explosive

gas

atmosphere

is

likely

to

occur

in

normal

operation

3.44.3 zone 2 an area in which an explosive gas atmosphere is not likely to occur in normal operation and, if it does occur, is likely 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 their conformity 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 may supply either bulk storage and/or a direct filling facility. A typical compressor, for example would be a multi-

16


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stage machine which may be directly or indirectly driven by an electric motor or an internal combustion engine. 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 in banks of multiple vessels to speed up filling, to optimise the station design and to limit the number of start/stop cycles 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. During transportation the mobile storage with or without on board compressor shall comply to ADR regulations. In all other situations this standard applies.

5.5 Dispenser 5.5.1

Components

A dispenser comprises for example: ď&#x201A;ž

a dispensing and optional metering unit;

ď&#x201A;ž

a filling hose;

ď&#x201A;ž

a filling nozzle.

Gas for dispensing is drawn either directly from a compressor or via on-site storage, and then passed into the vehicle. 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 (if any). 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 security systems 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 the dispenser.

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 into account 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 be assembled 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. These shall be supported by appropriate certification (for example EN 10204). These shall be installed and used in accordance with the manufacturer's instructions. Consideration shall be given to depressurisation of pressurized components e.g. for removal for maintenance purposes, draining condensate, by the provision of valves and gauges to ensure that sections are depressurised before service interventions. 6.1.1

Materials

The following standards when used in conjunction with the relevant design code such as, but not limited to current versions of those listed in informative annex K may be acceptable, but will not automatically fulfil the requirements of directive 97/23/EC. The manufacturer of the station shall ensure that all material used for the construction of the station conforms to the required specifications. In particular, documentation provided by the material manufacturer affirming compliance with the specification must be obtained for all materials used for the production of pressure carrying components. For the main pressure-bearing parts this shall take the form of a certificate of specific product control in accordance with EN 10204 prepared by the material manufacturer affirming compliance with the material specifications within this sub-clause. The manufacturer of the station shall document the compliance with the design and material specifications. He shall use one or more of the appropriate standards as used for the construction of pressurized parts. These materials shall: a. have suitable properties for all operating conditions which are reasonably foreseeable and for all test conditions. In particular, they should be sufficiently ductile and tough. Moreover, due care should be exercised 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 produced gases; c.

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not be significantly affected by ageing;


prEN 13638:2007 (E)

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 put together.

Compliance with the design and material specifications of the pressure equipment directive is given by one of the 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, EN ISO 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, EN 10027-1, 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 102774, EN 10277-5, EN 12164, EN 13445-1, EN 13445-2, EN 13445-3, EN 13445-4, ISO 683-1 for pressure vessels,

EN 1964-1, EN 1964-2, EN ISO 11120, ISO 9809-1, ISO 9808-2, ISO 9809-3 for steel cylinders of the storage unit.

The standards when used in conjunction with the relevant design code such as, but not limited to current versions of those listed in informative annex K may be acceptable, but will not automatically fulfil the requirements 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 of extraneous forces such as the effects of changes in temperature, and forces and vibrations set up during manufacturing and assembly. This implies proof of adequate strength either by calculation method or by experimental design method. All the elements of assembly shall be protected against corrosion by means of suitable 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 safety of the system. The properties of permanent joints must meet the minimum properties specified for the materials to be joined unless other relevant property values are specifically taken into account in the design calculations. Any joining of components may only be performed by a competent person. In particular, welded connections may only be produced by a welder qualified in accordance with the EN 287-1. The welding shall be carried out to a procedure as specified in EN ISO 15609-1 or EN ISO 15609-2 taking into account any necessary heat treatment and traceability of materials. Permanent joints shall be subject to non-destructive tests carried out by suitably qualified personnel, e.g. in compliance 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. Special consideration 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 consideration shall be given to safety and ventilation requirements. Electric and non-electrical equipment and/or components shall be either explosion protected or located in areas 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 explosive atmospheres (hazardous area), shall be designed and manufactured according to good engineering practice and in conformity with the required categories for group II equipment, to ensure avoidance of any ignition source, as mentioned in EN 1127-1. Equipment and components shall be suitable as a minimum requirement for Explosion Group IIA and temperature 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 EN 13463 – 1. Light alloy when used shall conform to the requirements of EN 13463–1. If other specifications for explosion protected 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 the measured 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 that 6 the resistance between nozzle and earth is less than 10 . 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 the dispensing 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 the composition 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 station and its pipework, and the uncontrolled release of pressurized gas. However, a short duration increase to 1,1 times the maximum allowable pressure is permissible. Safety devices shall be independent of other functions, unless their safety function cannot be affected by such other functions. They shall comply with appropriate design principles in order to obtain suitable and reliable protection.

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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 will work in such a way that the delivery pressure to the vehicle cannot exceed the maximum allowed delivery pressure. 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, exceed 260 bar irrespective of the ambient temperature. The maximum delivery pressure of the natural gas to the vehicle shall not exceed 200 bar above atmospheric pressure for refuelling stations without temperature compensation. It may be higher where temperature compensation 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 not exceeding 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 a height of at least 3 m above the ground, and at least 1 m higher than any buildings within a radius of 5 m; 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 restrictions and 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 as mentioned 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 a room 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 other sources 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 allow electrical equipment to be specified and other potential sources of ignition to be located. However, a complete drawing shall be produced prior to installation of the filling station and shall be based on Annex B. This annex is based on European standard EN 60079-10. 7.2.3 New and existing installations shall both comply with EN 60079 â&#x20AC;&#x201C; 10 when affected by new hazardous areas. 7.2.4 The hazardous area shall not exceed the boundary of the filling station unless a complementary risk analysis 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 individual banks of vessels, dependent upon design, to allow revalidation. Consideration shall be given to the protection of 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 of the filling position. 7.4.2 Where a slow-fill facility is provided, adequate protection shall be given against unauthorised interference, 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 is placed, 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 have unacceptable aspects, for example safety, security, noise levels, weather protection etc., consideration may be 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 the same compartment. 7.5.1.2 An enclosure used to house a compressor and/or a storage facility, including their respective ancillaries, 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 any potential 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 fireresistant construction, impermeable and of solid masonry or concrete. The wall shall be at least as high as the highest 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 supply network shall be sufficient to cope with the gas compressor suction requirements, and compressor operation shall 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 a minimum, 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 the compressor falling below an acceptable level, shall act onto the compressor to shut down and not to re-start automatically.

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8.1.4

Special equipment

It may be necessary to provide gas conditioning equipment, filters and pressure regulation which shall be designed 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 in respect 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 the transmission 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 unacceptable pressure pulsations. 9.1.5

Protection against weather

A compressor intended for outdoor installation has to be adequately protected against weather conditions to ensure 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 other person.

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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 a safety valve or pressure switch). A safety valve shall be provided for the final stage of the compressor (see EN 1012-1). NOTE: Each stage of compression should be equipped with a safety device to prevent overpressurising (i.e. by a safety valve 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 9.4.2

Resetting of the control system shall be undertaken manually. Relief Valve

The final stage shall have a full capacity relief valve which may vent to atmosphere or may vent to a recovery vessel, 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 downstream pressure 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 is not 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, legible manner on a firmly attached plate:  identification of the manufacturer and, where appropriate, identification of his authorized representative;  the year of manufacture;  unique identification of the compressor, such as type, series or batch identification and/or serial number;  essential limits such as maximum allowable pressures and temperature, (kilowatts) and supply voltage in V (Volts);

rated power in kW

 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 warnings concerning known hazardous practices, undesignated use and residual risks. The documentation shall be provided by the manufacturer. When brought into service, for all compressors the instructions shall be present in the original language and in translation into one of the official languages of the country of operation. The translation may be produced by the manufacturer, by its authorized representative or by the person importing 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 in view 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 and to 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

28

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 replacement intervals;

f)

Specifications of hydraulic oils;

g)

Pressure and temperature limits of the lubrication system;

h)

Environmental condition limits;


prEN 13638:2007 (E)

i)

Maximum and eventually minimum revolution number;

j)

The necessity to install pressure relief devices and other protective devices if they are not part of the delivery of the compressor;

k)

A warning to operate the compressor eventually in an explosive atmosphere unless it is designed for 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:

9.9.2.4

Safety measures to prevent ice and snow to affect the operation of the compressor, in particular that pressure relief devices, intake air filters for the compressor and for air cooling may 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 the lubrication system warm.

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 jobs and 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 not designed such to resist the pressures resulting thereof a warning shall be given and the location where the compressor 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. These duties 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 regular exchange;  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 compressor stations with more than one compressor;  Guidelines for the safe commissioning, decommissioning and partition of each unit in a compressor station 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 a repair manual exclusively for his authorized service personnel in a language, describing all the special duties required for a 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, with unmistakeable 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 13445-4 and EN 13445-5. 10.1.2 Means shall be provided to prevent any pressurised vessel from being isolated from its pressure relief device. For example for cylinders without their own pressure relief device this can be achieved by the removal of any isolation valve handle and the adoption of formal procedures to take any individual vessel out of service. 10.1.3 Precautions shall be taken in order to protect the storage facility from heat radiation (i.e. sun radiation).

10.2 Pressure relief devices 10.2.1 At least one suitable non temperature dependent safety device shall be fitted to protect the storage from over-pressurisation with a discharge rate that is adequate to ensure a controlled depressurisation of the system. 10.2.2 A suitable device that releases the pressure at a temperature of 100 ºC +/- 10°C when using steel pressure vessels shall be fitted to each manifolded group of vessels, in order to permit controlled discharge in the event of fire. In case pressure vessels made from other materials are used, it shall be proven that the safety device will operate 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 allowable pressure;

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 flexible connections.

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, EN 12007-2 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, or suitable 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 stainless steel pipe. 11.3.2.2 Where overhead pipework crosses any vehicle access way it shall be so positioned and protected to 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 that pipework 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 appropriate carbon 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 steel pipework shall be suitably protected by an anti-corrosion system. Stainless Steel pipework shall be buried in sand. 11.3.3.5 Where the piping is cathodically protected or other considerations call for it, insulated connections should 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 with adequate distances to avoid sparking. 11.3.3.7 When installing insulated connections outside the covered area of the filling station the section of underground 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 such that 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 be applicable. 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 and isolate the gas inlet. 12.2 The procedure shall shut down the compressor and isolate the outlets of any storage by the operation of automatic valves. The isolation should be made as close to the filling point as possible by means of fail safe operation 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 mechanical ventilation 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 be stopped. If more than one dispensing unit is connected to the storage, the delivery may be stopped with common valves.

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12.3 Emergency shutdown devices shall be suitably located throughout the filling station. Special attention to this 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 conditions in 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: ď&#x201A;ž

break away system. The disconnection force of the break away device shall be lower than 500 N for dispensers for personal vehicles and 850 N for high flow dispensers for commercial vehicles in any direction;

ď&#x201A;ž

automatic shut off valve(s). It may be required by local regulation to install a minimum of two automatic shut-off valves in series.

13.1.2 The dispensing unit shall be protected against vehicle collision. In case of damage to the dispenser despite the collision protector an automatic valve or excess flow valve shall be activated closing the supply to the dispenser at its inlet. 13.1.3 When connected to the vehicle, the vehicle and dispensing equipment shall be equipotential. This is usually 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 a button 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 shall comply with the requirements of ISO 15500-17. It shall be supported adequately or coated to prevent kinking and 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 exceed 5 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 be applied. 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 testing thereof is known. Therefore suitable regulations as e.g. national standards may be applied until publication of such European or International standard.

13.2.7 The hose shall be marked with the maximum allowable pressure, the year of production and the producerâ&#x20AC;&#x2122; 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 to operate 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 adequate connection 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 any vehicle 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 from entering.

13.4 Captive vent systems In the interest of protection of the environment, consideration should be given to collecting the small volume of gas 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 appropriate types 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 adequately bonded to a common earth.

14.3 Lightning protection Measures for protection against lightning shall be considered to limit the overloading of cables and electrical equipment.

15 Testing, purging and commissioning 15.1 The equipment shall be visually inspected and mechanically tested (i.e. compressors, valves, etc). This can be performed at the manufacturersâ&#x20AC;&#x2122; site. All pressure loaded equipment shall be pressure and leak tested and adequately purged and commissioned. Upstream of the compression unit, consideration should be given to 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 documentation and 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 where it 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 body may be CE-marked by its manufacturer. In addition, the NGV filling station shall carry the following markings in a durable, legible manner on a firmly attached data plate: 

identification of the manufacturer and, where appropriate, identification of his authorized representative established 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 of regenerative 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 immediately adjacent to each filling hose; for other filling stations the instructions shall be easily accessible for the personnel. The instructions shall include the relevant safety precautions especially non-smoking, turn off engine. All signs shall 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 fuelling stations 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 visual inspection 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 understanding of the instructions. Where pipework is installed underground, the positioning and routing of the underground pipework shall be recorded 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 â&#x20AC;&#x201D; 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

Around the openings without specific study or calculation use r = 1 m with using a grade of release of 3 0,002 m / s and the code developed by G. OOMS (see bibliography ) r = 0,25 m

40

Figure A.3 — Hazardous areas at storage unit


prEN 13638:2007 (E)

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 and the 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 the receptacle). 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 of release 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: ď&#x201A;ˇ If they comply with national regulations and GRPE standards: NHA around vehicles ď&#x201A;ˇ Venting volume of 120 normal m through a pipe of 55 mm internal diameter calculation made with the code developed by G. OOMS (see bibliography) 3

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Annex B(informative) Safety distances

EQUIPMENT

MINIMUM REQUIREMENTS

Distance between CNG dispenser and other fuel dispensers, should be determined according to the respective 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 the storage and dispenser and the property boundary and building openings, other sources of ignition should also 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 event and 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 stored gas volume of up to 10.000 l water capacity at 250 bars. Special consideration should be given to larger volumes  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. The distance 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 by means 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 includes the 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 is given in EN 60079-10. Equipment, used in hazardous area, shall be in accordance with the equipment categories as 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 by mixtures 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 by gases, 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 by gases, vapours or mists are unlikely to occur or if they do occur, are likely to do so infrequently and for a short period 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

n

EN 60079-15

-

-

A

i

EN 60079-25

A

A

A

EN 60079-26

A

A

A

EN 60079-0

A

A

A

Non sparking Intrinsically safe electrical systems General requirements for Category 1 equipment General requirements

A = allowed

Any non-electrical equipment, intended for use in a potentially explosive atmosphere, shall comply with the requirements of EN 13463-1. To assess the category of the equipment it shall be subjected to an ignition hazard assessment 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 with clause 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 nozzle may 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 fill post, 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 the components 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 with at 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 or the supplier of the instruments. A complete documentation, containing the proof of conformity to specification of the components, shall be prepared and 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, at 1,43 times the maximum allowable pressure. This test may be either performed on site or at the premises of the manufacturer 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 shall be 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 provide drainage 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 the maximum allowable pressure then stop the pressurizing pump. During this period, plot the pressure reading against time elapsed.

E.2.5 On reaching the test pressure, continue to plot pressure against time elapsed for a minimum of 1 h, recording any pressure 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 sudden drop 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 of the equipment. NOTE: Instead of a hydrostatic test a pneumatic test may be applied when safety for any person in the area (personnel and general 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 of separately tested small bore pipework together with other equipment, subject the completed system to a pneumatic leak 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 period adequate 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 detection fluid. 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 to national 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 have carried out measurements, inspections or check-ups, the results should be stored and kept available for authorised inspection officers at least until the results of the next measurement, inspection or check-up are available, unless it is stated otherwise in the applicable national or local regulations.

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Annex G(informative) Safety precautions for hydrostatic and 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 any procedure which would violate this concept. All personnel engaged in testing will need to be instructed fully regarding the possible hazards involved in the testing, particular attention being paid to securing pipes to prevent whip following any failure.

G.1.2 Consult at the pipework design stage with the designer on the adequacy of the safety precautions proposed by the contractor. The safety precautions will need to ensure that, as far as possible, no person is exposed to injury should any part of the pipework system fail during the test operation. The safety precautions will need to be subject to 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 out previously 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 the pipework runs and local access ways. The boundaries of the test area shall be defined by marker tapes. Display proper warning notices reading "WARNING - STATION UNDER TEST" at all points where access may be gained to 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 pressure from 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 order to prevent condensation within the pipework, do not allow the temperature of the test medium to fall below the dew point 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 large quantity of dry air or nitrogen, with a dew point below -40 C, through the system until the dew point of the exit gas is -40 C. At this stage, leave the inlet and outlet of the pipework to stand to allow the dry gas to absorb any small residual pockets of water, and then carry out a further dew point check which, for acceptance, will need to be -40 C 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 the installation.

H.2.4 Take precautions to reduce, as far as practical, the possible hazards arising from venting, for example by avoiding venting close to property or potential sources of ignition such as electrical plant and equipment. Warning notices, in particular "No Smoking" and "No Naked Lights", will need to be displayed prominently around the area where purging 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 gas suppliers' 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 the purge gas to meet the criteria of the purge.

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prEN 13638:2007 (E)

H.3.2 Purging from gas to air or air to gas can be carried out providing a minimum velocity within all the associated pipework 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 would be nitrogen.

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prEN 13638:2007 (E)

Annex I(informative) Example of filling plan with three bank system and two 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 â&#x20AC;&#x201D; 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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prEN 13638:2007 (E)

Annex K (informative) Reference standards applied for materials in the construction 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 for construction 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 for pressure 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 carbon and 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-Temperature Service

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 HeatExchanger and Condenser Tubes

ASTM A 182/A

Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged fittings, and Valves and Parts for High-Temperature Service

ASTM A 193/A

Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service

ASTM A 194/A

Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both

ASTM A 234/A

Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

55


prEN 13638:2007 (E)

ASTM A 262/A

Standard Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steel

ASTM A 269

Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

ASTM A 312/A

Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A 333/A

Standard Specification for Seamless and Welded Steel Pipe for LowTemperature Service

ASTM A 334/A

Standard Specification for Seamless and Welded Carbon and Alloy-Steel Tubes for Low-Temperature Service

ASTM A 350

Standard Specification for Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness 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 Moderateand Lower-Temperature Service

ASTM A 576-90b

Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality

56


prEN 13638:2007 (E)

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 member states relating to electromagnetic compatibility

98/37/EC

Directive 98/37/EC of the European Parliament and of the Council of 22 June 1998 on the 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 the provision 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 on the approximation of the laws of the Member States concerning equipment and protective 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 on the 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: Basic terminology, 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: Titration procedure

ISO 10101-3

Natural gas – Determination of water by the Karl Fisher method – Part 3: Coulometric procedure

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

57


prEN 13638:2007 (E)

Annex ZA (informative) Clauses of this European Standard addressing essential requirements or other provisions of EU Directives.

This European Standard has been prepared under a mandate given to CEN by the European Commission to provide 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 has been implemented as a national standard in at least one Member State, compliance with the clauses of this standard given in table ZA confers, within the limits of the scope of this standard, a presumption of conformity with the corresponding Essential Requirements of that Directive and associated EFTA regulations. Table ZA â&#x20AC;&#x201D; Correspondence between this European Standard and Directive 97/23/EC Essential requirement

58

Object

Clauses in the standard which comply wholly or partly 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 allowable limits of pressure equipment

6.3.1, .6.3.2, 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

9.4.1,

9.4.2,


prEN 13638:2007 (E)

Table ZA (continued) Essential requirement

Object

Clauses in the standard which comply wholly or partly with the essential safety 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

6a

11.1; 11.3.3.4; 11.3.3.7

6b

9.3

6d

6.1.2, 9.1.3, 9.1.4

6e

13.1.1, 13.3.1

6g

16.5.2

59


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