1

1. ------IND- 2010 0010 RO- EN- ------ 20100203 --- --- PROJET

TECHNICAL NORM REGARDING THE

DESIGN, MANUFACTURE, OPERATION,

MAINTENANCE AND REPAIR OF STORAGE

AND DISTRIBUTION STATIONS FOR

COMPRESSED NATURAL GAS USED AS

VEHICLE FUEL (CNGV).

NTGNCV- 01: 2009

2

3

1. Aim and terminology

1.1. The aim of the present technical norm is to establish the minimum conditions

required for the design, manufacture, operation, maintenance, repair,

decommissioning and post-use of storage and distribution stations for compressed natural gases used as fuel in vehicles equipped with engines converted for this type

of fuel (hereinafter “compressed natural gas” – CNGV), as well as the group of preventative and operational intervention measures to be taken in order to reduce the

social, economic and ecological consequences if any events occur in these systems.

1.2. The present technical norm shall apply to products that are lawfully marketed in

another Member State of the European Union in accordance with the provisions of Regulation (EC) No 764/2008 of the European Parliament and of the Council of 9

July 2008 for laying down procedures relating to the application of certain national technical norms to products lawfully marketed in another Member State, and

repealing Decision No 3052/95/EC.

1.3. The design and manufacture of storage and distribution stations for CNGV must

ensure that the operational quality and safety requirements are met, in accordance with the legislation in force.

1.4. The terminology used in the present technical norm has the following meanings: site the area where a CNGV storage and distribution station is used

or is going to be installed cylinder a pressurised recipient equipped with a direct connection fitting,

used to store CNGV storage cascade represents cylinders or sets of cylinders used for pressurised

CNGV storage compressor a mechanical device that increases the pressure of the natural

gas by reducing its volume; the gas pressure increases as the

temperature increases leak detector a device, usually incorporated in a system, which detects the

presence of a dangerous concentration of natural gas in the

CNGV storage and distribution station, and triggers an alarm system or shuts down the station

dispenser any mechanical or automatic device, either stationary or mobile,

which is used to dispense CNGV in a CNGV storage and

distribution station compressed natural

gas distribution the group of procedures, methods, equipment and possibilities

that are designed and interconnected so that they facilitate and monitor the sale of CNG to customers at the storage and

distribution station safety distance the minimum distance between a source of danger and an

object (human, equipment or environment), which must reduce the effects of any probable unforeseen event and prevent a

minor incident turning into a large-scale incident protective distance the separation distance recommended for people, for different

situations of danger in which CNGV leaks have occurred

4

risk phrase a phrase that provides a concise description of the risk that

CNGV poses to humans and the environment danger phrase a phrase that provides a concise description of the danger that

CNGV poses to humans and the environment compressed natural

gas a mixture of hydrocarbons, in either gaseous or vapour phase,

mainly consisting of gaseous methane, which is compressed

and used as vehicle fuel hopcalite a mixture of copper and manganese oxides used as a catalyst

to convert carbon monoxide to carbon dioxide when exposed to

the oxygen in the air. odorisation the process of incorporating an odorant in CNGV, for safety

reasons vehicle compressed

natural gas supply operator

an employee of the undertaking that operates a CNGV storage

and distribution station, who is responsible for filling up vehicles (Nomenclator for the Classification of Economic Activities, code

932002 – bottler of pressurised fluid into cylinder recipients installed on recreational boats or vehicles)

operating pressure the pressure at which the station is operated when the pressure

is less than or equal to the design pressure transfer point the point where the CNG dispenser is connected to the vehicle

(Figure 3a) hydrocarbon dew point

the temperature above which condensation does not occur at a specified pressure

purging temporary evacuation which causes CNGV to be discharged

(purged) into the atmosphere gas leak any loss of NG caused by a malfunctioning or damaged

component of the CNGV storage and distribution station CNGV storage and distribution station

a system made up of devices, cylinders, pipes, fittings, armatures, compressors, pressure regulators, safety valves,

ventilation systems, mechanical and acoustic protection

systems, dispensers, tax registration systems, etc. intended to

be used to compress, store, distribute and transport CNGV to be used as vehicle fuel

purging time the time interval required to purge a part of or the entire equipment before evacuating the air or any remains of CNGV

compression unit the unit that compresses the natural gas and consists of one or

more compressors, including all related pipes and equipment

2. Field of application

2.1. The present technical norm shall apply to the following CNGV storage and

distribution stations:

(1) Independent stations:

1. Stationary mother station – an assembly of equipment connected to

the natural gas pipeline, which has a compression system that allows pressurised filling of a cascade of cylinder sets for CNGV distribution as well as sets of

transportable cylinders and tubes, or can provide in-line filling of CNGV cylinders fitted on vehicles (see Figure A2.1); it can belong to one of the following

constructive types:

a. with cascade compression in two sets of cylinders;

5

b. with cascade compression in two sets of cylinders and directly to the

vehicle filling point; c. with cascade compression in three sets of cylinders and directly to the

vehicle filling point; d. types b and c, with the possibility of an external cascade;

e. type b, with intermediate cooling of CNGV;

f. type b, with intermediate pressurisation of CNGV, using a hydraulic

compressor;

g. with cascade compression in three sets of cylinders and directly to the

dispenser or to the vehicle that transports the cylinders to the daughter station;

h. with cascade compression in three sets of cylinders and directly to the

vehicle filling point;

i. with cascade compression in a set of cylinders, with the option of an external cascade.

2. Stationary daughter station – an assembly of facilities that are not connected to the natural gas pipeline, which distribute CNGV from a mobile cascade

of cylinder or tube sets – of the following constructive types:

a. with pressurisation provided by a hydraulic compressor from the set on

the lorry; b. with pressurisation provided by a hydraulic compressor from the set on

the lorry and injection into the set of the daughter station; c. with pressurisation provided by a hydraulic compressor from the set on

the lorry, with the possibility of injection and pressurisation in a cascade of three

cylinder sets.

3. Mobile daughter stations of the constructive types given in 2.1.(1) 2;

(2) (Mixed) stations shared with other vehicle fuel distribution stations:

a. stationary mother or daughter stations; b. mobile daughter stations;

(3) Mother stations can be built as an individual or modular compact system of

various capacities, or on different levels.

2.2. The present technical norm does not apply to stationary domestic devices

designed to compress natural gas for filling up private vehicles at home; specific regulations shall be drawn up for these.

2.3. (1) The technical quality and safety requirements for using NG as vehicle fuel

must include the following:

a. composition (especially butane-propane components);

b. water content; c. carbon dioxide content;

d. total sulphur compounds (from odorants and sulphuretted hydrogen); e. methanol content;

f. oxygen content;

g. powder and mechanical particle content;

h. oil content;

6

i. hydrocarbon dew point;

j. Wobbe index; k. anti-knock index,

in accordance with the recommendations issued in SR EN ISO 15403-1 Natural gas. Natural gas for use as compressed fuel for vehicles. Part 1: Designation of the

quality. (2) The required level of odorisation must also be ensured after the drying

treatment applied to natural gas before compression, whilst the odorant used must not affect the operation of the engine and/or activity of the exhaust gas treatment

catalyst.

2.4. A schematic diagram of a CNGV storage and distribution station is given in

Annex No 2 (Figure A2. 1).

3. General requirements for CNGV storage and distribution stations

3.1. CNGV storage and distribution stations shall be located on sites that are especially designed for the distribution of this type of fuel, after assessing the

essential safety requirements, which include the following: - identification of the dangers;

- identification of the personnel who are exposed to these dangers;

- qualitative or quantitative risk assessment;

- assessment of the possibility of eliminating or reducing risks.

3.2. The following principles must be followed when determining the site for the

station: a. compliance with the legislation on siting vehicle fuel distribution stations;

b. geographical and administrative delimitation of the site;

c. determining the size of the station in accordance with the potential for using

CNGV in the area surrounding the site; d. providing access for the emergency services;

e. providing emergency routes for evacuating personnel; f. interaction with other systems within the site;

g. restricting the areas with an increased risk of flammable gas leaks, by

delimiting them;

h. safety during operation and maintenance; i. interaction between facilities located within the site, such as access routes,

sewage and utility routes; j. presence of safety distances – separation up to the minimum possible distance

that will reduce the risks incurred by loading/unloading operations carried out

between the station and the storage unit;

3.3. (1) When choosing the site, aspects relating to the type of station, type of vehicle fleet, filling volumes and surface area of the site must be taken into

consideration. (2) The systems of CNGV storage and distribution stations must be protected

against the access of unauthorised persons and any potential acts of terrorism.

(3) It is prohibited to place objects in gangways, passageways, corridors,

basements, etc. to avoid blocking the circulation, evacuation or access routes of the site.

7

(4) The site of the CNGV storage and distribution station must be flat and take

into account the geotechnical characteristics of the ground.

3.4. Depending on their constructive type, CNGV storage and distribution stations are

made up of the following components: a. NG compression system and auxiliary equipment (driers, decanters, purgers,

etc.);

b. priority control panel;

stationary cascade of storage cylinder sets or the cascade of transportable cylinder sets or tubes, respectively;

c. CNGV filling equipment; d. CNGV technological pipe system;

e. system for filling up cylinders or tubes with CNGV for transportation to the

daughter station;

f. foundations; g. acoustic cabin;

h. buildings (structures) of the CNGV storage and distribution station; i. CNGV leak detection, warning and fire extinguishing systems.

j. fencing of the station.

3.5. (1) A CNGV storage and distribution station is defined by the following

characteristics: a. site;

b. type of station: public or for special use (refuelling buses, special vehicles, etc.);

c. type of compressor;

d. type of dispenser;

e. average flow rate, in kg/h (m3/h); f. suction and discharge pressure, in MPa (bar);

g. operating pressure, in MPa (bar); h. maximum load, in vehicles per hour;

i. average load, in vehicles per day;

j. designed filling time, in minutes.

(2) Vehicle cylinders can be filled with CNGV in the CNGV storage and distribution station in the following ways:

a. quickly – using the CNGV from the cascade of storage cylinder sets of the station; to be used when aiming for accurate monitoring of the quantity of CNGV

supplied to each and every vehicle, especially in public stations;

b. in-line (in time), or sequentially in-line – using the compressor directly,

without using the cascade of storage cylinder sets; the filling is carried out during the night and the quantity of CNGV is distributed concomitantly to the vehicle cylinders

and is difficult to monitor; for this reason, this is used in stations designed for special uses (to refuel buses, special vehicles, etc.);

c. combined – includes both versions given in 3.5. a, b;

d. with or without temperature compression – taking into account the weather

conditions and any other elements such as: cylinder safety coefficient, the material that the cylinders are made of, the material that the thermal insulation is made of

(these elements shall be taken into consideration during the design stage).

8

(3) The station design capacity can be determined as a function of the

vehicle fleet to be refuelled, in accordance with Table A2.1.

3.6. (1) The concept of mother – daughter station refers to collecting the NG from

the supply pipe, compressing it in stationary cylinders or transportable cylinder or

tube sets designed to store CNGV and transport it to the mother station and

transporting them to the daughter station using special lorries or trailers; the two stations shall be located within a distance from each other that, in specific traffic

conditions, will ensure safety during transportation. (2) At the daughter station, vehicle cylinders can also be filled up with CNGV

directly from the set of cylinders or tubes located on the trailer or lorry, at a pressure

of 20 MPa.

(3) The pressure inside the CNGV cylinders at the daughter station must be stabilised using a compressor; when the pressure inside the cylinder cannot be

stabilised, the trailer or lorry shall return to the mother station to be re-filled.

Measuring and recording the quantity of NG

3.7. (1) The CNGV storage and distribution station has access to the natural gas

transport or distribution system in accordance with the specific national legislation.

(2) The quantity of NG traded for use in the CNGV storage and distribution station shall be measured using a gas meter that meets the metrological

requirements for accuracy class 1.5 and has a maximum/minimum output ratio of at least 150. The gas meter is placed on the market and set into operation in

accordance with the provisions of the national legislation. The measuring information

supplied by the gas meter is used to perform the control, regulation, reporting and

recording functions. (3) The delivery point shall be considered in accordance with the definitions

given in Article 3.7 of SR EN ISO 12007-1 Gas supply systems. Pipelines for maximum operating pressure up to and including 16 bar. Part 1: General

recommendations or Article 3.2.2 of DIN EN 1775 Gas supply. Gas pipelines for

buildings. Maximum operating pressure = 5 bar; Functional recommendations. The

location of the separation fitting on the outlet pipe of the transport or distribution system meter is shown in Annex No 2, Figure A2.2.; it can be located near petroleum

product stations. Their active areas are allowed to intersect. (4) The supply of the CNGV storage and distribution station must not be

affected by the natural gas supply of any other user.

NG compression system and auxiliary equipment

3.8. (1) An NG compression system is made up of piston compressors with one or more compression stages, which are activated by various types of motors (electric,

combustion, hydraulic, pneumatic, etc.) that are designed and built to be used in potentially explosive atmospheres and ensure the same operating conditions for the

compressors.

(2) The natural gas compression system must be built in accordance with

the essential health and safety requirements for industrial machines, and must meet the following performance requirements:

a. to operate within the designed and guaranteed parameters;

b. to comply with the technical specification and bear an EC mark;

9

c. to display all information specific to the detailed diagram of the compression

unit, geometry, discharge devices (safety valves), weight, etc. d. to comply with the specified pressure drop;

e. to display the start-up diagram under safe conditions; f. to be equipped with diagrams for all pressure load combinations, all loading

steps and all their related speed gears;

g. to be equipped with temperature diagrams specific to the pressure

combinations, for all loading steps, all related speed gears and different operating outputs;

h. to have all performance curves for the speed variation loads, both for suction and discharge, as well as for the operating outputs;

i. to revise the possible flow trends and, implicitly, the specific noise diagrams.

(3) The technical specification of the compressor must include at least the

following information: A. Data about the compressor:

a. name of manufacturer; b. model/type of compressor;

c. number of rotations or cycles per minute;

d. (absolute) maximum suction pressure, in MPa (bar);

e. (absolute) minimum suction pressure, in MPa (bar); f. (absolute) maximum discharge pressure, in MPa (bar);

g. diameter of the first stage cylinder; h. length of the piston stroke, in mm;

i. number of compression stages;

j. (absolute) stage pressure, in MPa (bar);

B. Output/suction pressure diagram, or equivalence table; C. Details about shutting down, alarms and warning systems; D. Information about the auxiliary equipment of the compressor:

a. cooling system;

b. lubricating and sealing system;

c. internal fire extinguishing system;

d. system responsible for activating the fire extinguishing system; e. pulsation dampeners;

f. type of anti-seismic and anti-vibration insulators; g. sound insulation systems;

h. smoke detectors, high temperature detectors, gas detectors, etc.;

E. Compressor actuating system: a. technical data regarding the electric motor (manufacturer, type, model,

speed, anti-explosion protection, intrinsic safety);

b. technical data regarding the internal combustion engine (manufacturer, type, model, conditions for turning on/shutting down, etc.);

F. Information required for maintenance and repair of the compressor and its auxiliary equipment.

(4) The electric motor must be built in an Ex construction suitable for the working fluid, in accordance with the essential safety requirements for:

a. Protection equipment and systems designed to be used in potentially

explosive atmospheres; b. Ensuring safety for the users of low voltage electrical equipment; c. Electromagnetic compatibility; d. General product safety.

10

(5) The compressor must be connected to a gas combustion engine by means

of a flexible coupling. (6) Operation with no vibration of the compressor must be ensured by isolating

it from the rest of the equipment by means of elastic shock and vibration dampeners. (7) The level of vibration must be checked by a vibration detector installed on

the NG compressor casing, which would signal any vibration increase above the

accepted level.

3.9. (1) The natural gas must be sucked into the compressor after its preliminary filtration and drying by adsorption (also see the recommendations of SR EN ISO

15403-1 Natural gas. Natural gas for use as compressed fuel for vehicles. Part 1: Designation of the quality), and must be controlled at all times.

(2) For static and/or regenerative systems, drying must be carried out in both

the pre-compression stage (low pressure) and the post-compression stage (high

pressure). (3) Drying efficacy is affected by the dew point of NG, input pressure and

average output of the compressor (in accordance with SR EN ISO 15403-1). (4) The dew point of the NG used to supply the CNGV storage and distribution

station must be considered for a pressure of 1 to 1.5 bar relative pressure, and must

be between minus 40 °C and minus 20 °C, for operating pressures between 200 and

250 bar relative pressure, for a compression factor ranging between 130 and 250 times in relation to the station supply condition, for a saturation condition in which the

condensate must be dried in accordance with the recommendations of SR EN ISO 15403-1.

The dew point for the hydrocarbon components of the NG is the major factor

that indicates whether, at a given pressure and temperature, the natural gas flow

inside a pipeline is in a gaseous state only, or in both gaseous and liquid states. (5) Drying must normally be carried out by adsorption, by contact with

adsorbent elements over time, depending on the way in which the following recommended agents are used:

a. activated carbon for the adsorption of hydrocarbons and other organic

vapours;

b. molecular sieves for the adsorption of: carbon dioxide, nitrogen, sulphuretted hydrogen, nitrogen oxides, amines, aromas;

c. silica gel or mist separators for the adsorption of water vapours; d. mixed bases for mixtures of acidic gases, carbon dioxide, sulphur oxides,

nitrogen oxides, hydrochloric acid;

e. potassium permanganate for the adsorption of sulphur oxides and other

acidic gases;

f. hopcalite for the adsorption of carbon oxide from the catalytic oxidation of

carbon dioxide, etc.

(6) If considered necessary, the compression stages shall be equipped with

separators for the natural gas condensed between stages.

3.10. (1) All pressurised elements must be safe for a temperature 20% higher than the discharge temperature of each stage; the initial temperature of each stage must

not exceed a maximum of 50 °C, whilst the discharge temperature of each stage must not exceed 200 °C, at a reference temperature of 20 °C; this means that the

compressed natural gas must be cooled between the compression stages by means

of air coolers.

11

(2) The compressor cylinders may be equipped with fins to increase the

compressed natural gas cooling surfaces. (3) The pipes located between the pressurisation stages of the natural gas

compressor must be equipped with high temperature protection and intermediate pressure transducers.

3.11. (1) Oil separators with either continuous or intermittent purging must be

installed between the natural gas compression stages, in order to separate all traces

from the compressor lubricating and sealing oil. (2) Separation of the oil must also include coalescence filters that ensure the

supply of clean and dry compressed natural gas. (3) Operation and presence of lubricating and sealing oil between the stages

shall be checked using portholes, which must be an integrated part of the lubricating

and sealing system.

(4) The lubrication and sealing must be checked by a sensor that monitors the constant level of the oil in the oil pan.

3.12. If considered necessary, pressure relief/equalising dampeners (pulsation or hydraulic equalising dampeners) will be installed on the suction of the natural gas

compression stages.

3.13. A regulating and control fitting must be installed on the suction pipe of the

compressor, in order to ensure constant suction pressure.

3.14. The compressor must be equipped with a depressurisation fitting, to facilitate

easy shut-down and start-up.

3.15. To avoid excessive pressure increase, each pressurisation stage must be

equipped with safety valves that will discharge the excess pressure.

3.16. (1) The enclosure where the natural gas compressor is located must be

equipped with CNGV leak detectors that will be calibrated so that they emit a visual (red light) and sound alarm when 10% of the lower explosive limit (LEL) is reached,

and trigger the shut-down when 20% of the lower explosive limit (LEL) is reached. (2) The response time of the leak detectors must be less than or equal to 20

seconds, whilst their return time must be less than or equal to 30 seconds.

3.17. (1) The ventilation pipe of the enclosure where the natural gas compressor

is located must be equipped with a flame arrester. (2) The flame arrester must comply with the recommendations of SR EN

12874 Flame arresters. Performance requirements, test methods and limits for use, the essential safety requirements for protection equipment and systems designed to

be used in potentially explosive atmospheres and the recommendations issued in

CENELEC Report R044-001.

(3) The flame arrester shall be installed using an anti-deflagration fitting manufactured in accordance with the requirements stipulated in Paragraph (2).

12

3.18. (1) The enclosure where the natural gas compressor is located must be

equipped with the following: a. flame detectors;

b. discharge system for the static electricity accumulated by activation; c. temperature transducers that indicate any unjustified increase of the

temperature within the location.

3.19. (1) The natural gas compressor must be equipped with a socket

specifically designed for gas sampling, so that chromatographic analyses of the quality of the NG can be performed whenever necessary.

(2) The location of the sampling points for gas chromatography must be chosen so that it does not lead to equivocal measurements.

3.20. Auxiliary equipment must be appropriately fixed to the foundations depending

on the seismicity of the location, and must be ensured against any accidental

displacement and be earthed.

3.21. Electrical and control equipment must be provided with anti-explosive and

anti-deflagration protection.

3.22. The internal combustion engine that activates the compressor must be built in

accordance with the essential health and safety requirements for industrial machines,

and must be equipped with a pneumatic start-up system and an explosive mixture detector, both installed at the location of the engine (see Article 3.17).

3.23. The compressor equipment must be fitted with safety interlock systems that will shut-down the compressor and NG supply in case of any malfunction, in accordance

with the recommendations of SR EN 14382 Safety devices for gas pressure

regulating stations and installations. Gas safety shut-off devices for operating

pressures up to 100 bar.

3.24. (1) The electrical installation shall be designed and made in accordance with

the regulations regarding the design, execution, inspection and operation of electrical

installations in areas that pose a risk of explosion, and in accordance with the

essential safety requirements for protection equipment and systems designed to be

used in potentially explosive atmospheres. (2) An electrical panel responsible for controlling the activation of the

compressed natural gas compressor, located in an area with a potentially explosive atmosphere, must have an Ex construction.

(3) The power supply of the CNGV compressor must be able to be cut off by

the following:

- local switch located inside the local electrical panel of the system; - general switch located in the general switchboard;

- power supply cut-off button for emergency situations. (4) The power supply of the compressed natural gas compressor must be

ensured so that continuous operation of the station is also ensured.

13

Priority control panel

3.25. (1) The priority control panel must ensure priority to the distribution of CNGV

in the cascade of pressurised storage cylinder sets, or directly to the distribution

pump or the station for direct filling from the compressor, and must include two

control subassemblies: an electronic sequential control subassembly that triggers a response in a mechanical control subassembly.

(2) The construction of the priority control panel must be appropriate for the type of station – either mother or daughter - that it serves, and can be mechanical or

automated. (3) The priority control panel must be easy to operate and prevent the flow of

CNGV from returning to the station system; (4) The priority control panel must be easy to maintain and operate; the priority

control panel must not be operated whilst the station is in operation; (5) The priority control panel must be equipped with safety fittings for

shutting-down the station, as well as safety valves;

3.26. The priority control panel must replace the manual control of CNGV distribution

within the CNGV storage and distribution station.

3.27. The priority control system must be installed directly in the open air or under a

weather canopy, on a stable foundation provided with anti-seismic protection.

3.28. The priority control panel shall be made in a simple constructive type or in Ex

version, depending on the protection area where it will be located, and must be

equipped with a weather isolation system.

3.29. The priority control panel shall be connected to the ground strap of the CNGV storage and distribution station.

3.30. The priority control panel shall be equipped with control instruments compatible with and calibrated for CNGV, and must be built as an energy saving

system.

3.31. The priority control panel must ensure immediate cessation of CNGV

compression, storage and distribution whenever the designed parameters of the station are exceeded.

3.32. The priority control panel shall prioritise on guiding the CNGV first in the high pressure cylinder set, then in the medium pressure cylinder set and, in the end, in the

low pressure cylinder set.

3.33. The priority control panel must be connected to the control system that monitors

the entire station.

The cascade of CNGV storage cylinder and tube sets

3.34. (1) The cascade of CNGV storage cylinder sets is made up of three high, medium and low pressure cylinder sets, whose total capacity is recommended to

equal at least one hour of continuous operation of the compressor.

(2) Mini-spherical pressurised recipients can also be used to store CNGV

inside stations.

14

(3) The cylinders in a set can be mounted horizontally or vertically; cylinders

that are mounted horizontally shall comply with the recommendations given in Figure A2. 3, in order to ensure permanent drainage of any potential traces of condensate.

3.35. It is recommended that each set of cylinders or tubes is identified by means of

colours applied to the entire surface of the cylinders/tubes, or only by a single painted

band applied to a width of 100 mm under the upper shoulder of each cylinder, in

accordance with the recommendations of SR EN 1089-3 Transportable gas cylinders. Gas cylinder identification. Part 3: Colour coding.

3.36. (1) High pressure cylinders that made up the CNGV storage cylinder cascade

inside stations or within the storage system mounted on the vehicle can belong to

one of the following types:

a. type 1 – steel or aluminium cylinders; b. type 2 – cylinders with a steel or aluminium liner wrapped in composite

materials; c. type 3 – cylinders that are completely bound to a metallic liner;

d. type 4 – cylinders made of composite materials

(2) The cylinders can have one or two shoulders; no welding seams are

permitted on the pressurised cylinder body. (3) Each cylinder must be equipped with a manual fitting or a normally closed

fitting whose activation is controlled from the priority panel, which would enable its individual isolation in the event of a malfunction, without affecting the operation of the

cascade, mounted using a protected system.

(4) Each cylinder must be secured and protected against corrosion with two

layers of anti-corrosive primer and two white or aluminium-coloured finishing layers. (5) Metallic cylinders must be protected, as they are susceptible to corrosion,

especially galvanic corrosion and impact; cylinders made of composite materials must be protected because they are susceptible to mechanical defects (abrasion,

cuts, grinding cracks) and acid corrosion.

3.37. (1) Metallic cylinders and tubes must be made of compatible materials in

accordance with SR EN ISO 11114-1, SR EN ISO 11114-2, SR EN ISO 11114-3 and SR EN ISO 11114-4 Transportable gas cylinders. Compatibility of cylinder and valve

materials with gas contents (Parts 1, 2, 3, 4) and the specific natural gas requirements recommended for cylinders by SR EN ISO 11439 Gas cylinders.

High-pressure cylinders for the on-board storage of natural gas used as a fuel for

automotive vehicles, or for tubes by SR EN ISO 11120 Gas cylinders. Refillable

seamless steel tubes for compressed gas transport, of water capacity between 150 l and 3 000 l. Design, construction and testing, respectively, as well as the

recommendations of the standards specific for transportable pressurised equipment, UN-ECE Regulation R110 and the European Agreement concerning the International

Carriage of Dangerous Goods by Road (ADR.), and must bear the European mark

Π (pi).

(2) Cylinders made of composite materials must be manufactured in accordance with the recommendations of the standards specific for transportable

pressurised equipment SR EN 12257 Transportable gas cylinders. Seamless, hoop-wrapped composite cylinders, UN-ECE Regulation R110 and the European

Agreement concerning the International Carriage of Dangerous Goods by Road

(ADR), and must bear the European mark Π (pi).

15

(3) Each cylinder set must be equipped with safety devices that trigger at an

overpressure 20% higher than the normal operating pressure.

3.38. The maximum authorised weight of the vehicle that carries such cylinders or

tubes to the daughter station must not exceed 40 tonnes.

3.39. The pipe that connects the cascade of cylinder sets to the discharge pipe of

the compressor must be equipped with a one-way (non-return) safety fitting and must be made of stainless steel pipe; the connection to the dispenser must also be made

of stainless steel pipe of suitable diameters.

3.40. The CNGV storage cylinder cascade can be positioned vertically, with the

fittings in an upright position, or can be positioned horizontally, with the fittings

pointing in the direction with the minimum risk.

3.41. In daughter stations, CNGV can be dispensed from the cascade of transportable cylinder sets, as well as pressurised tube sets.

CNGV filling equipment

3.42. The filling equipment of a CNGV storage and distribution station can be: a

dispenser or filling point, which must operate regardless of the NG composition, humidity, temperature and pressure, in accordance with the model approval, or bear

an EC mark:

a. within the temperature range from minus 40 °C up to plus 65 °C, and within

an operating pressure range of up to 25 MPa (250 bar); b. within a filling flow rate range up to 50 kg/min;

c. within the accuracy range of the mass flow rate measured for each filling system and with the guarantee that the flow rate will be stable when filling within the

accepted calibration range;

d. with the possibility to connect to the regulating system from the priority

control panel; e. under conditions of perfect anti-corrosion protection;

f. under suitable ergonomic conditions; g. adapted to the tax software of the station.

3.43. (1) The dispenser must be used when aiming to monitor the exact quantity

of CNGV dispensed to each refuelling vehicle, especially in public stations, during

quick filling by using CNGV from the storage cylinder cascade of the station. (2) The filling point must be used when filling is performed in-line (in time),

directly from the compressor, and the quantity of CNGV is dispensed to the vehicle cylinders at the same time and is not easy to monitor; for this reason, this is used in

special use stations (refuelling buses, special vehicles, etc.).

(3) The dispenser must be designed so that it automatically resets to zero

after each sale.

3.44. The dispenser must measure the quantity of CNGV dispensed, in kg, and

meet the metrological and technical requirements stipulated by the national metrology legislation. The dispenser must display the tax information (quantity dispensed, price

per measurement unit and total amount to be paid) on a device, and memorise the

data recorded for the period of time required by the tax legislation in force.

16

3.45. (1) The dispenser and filling station can have one or two filling points

equipped with special flexible hoses made of CNGV-compatible materials, a system that ensures retraction of the hose when filling is completed and emergency

disconnection in the event of an involuntary movement of the vehicle, as well as a filling cut-off function when the vehicle cylinders are full and have reached the

operating pressure (20MPa and 25Mpa, respectively) or when the hoses have been

damaged; the filling equipment is embedded in a protective case, and refuelling is

carried out without the need to open the protective case. (2) The disconnecting device in the event of an involuntary movement of the

vehicle during refuelling can be connected: a. directly to the filling hose of the dispenser and filling point;

b. to each filling panel of the mother station, which is used to fill the mobile

cylinder set located on the vehicle responsible for carrying the gas to the daughter

station; c. to each unloading panel of the daughter station.

(3) The dispenser and filling point must be grounded. (4) The dispenser and filling point must be surrounded and protected by a

protection system that can bear a 2 000 kg involuntary impact with vehicles travelling

at a speed of 20 km/h, and at a height of at least 30 cm between the position at which

the impact load is applied, in accordance with Figure 1.

Figure 1. Protection system for a dispenser and/or filling point

(5) The dispenser and filling point must be placed at an ergonomic height,

which would enable easy handling of the filler gun or nozzle.

(6) The dispenser and filling point must be identified by a 50x50 cm plate, according to the detailed view given in Figure 2, accompanied by the risk and danger

phrases.

Minimum 30 cm

17

(7) The dispenser and/or filling point must bear a plate that presents, both

explicitly and graphically, the connection - disconnection operations for the CNGV vehicle cylinder filler gun.

3.46. The dispenser must be able to perform filling:

a. in one step, using high pressure;

b. in two steps, using medium and high pressure; c. in three steps, using low, medium and high pressure in the CNGV storage

cylinder cascade.

3.47. (1) The dispenser and filing point must meet the essential safety

requirements for industrial machines, equipment and protection systems designed to

be used in potentially explosive atmospheres, the general product safety

requirements and the recommendations stipulated in standards. (2) Periodic metrological verification must be carried out in accordance with

the metrological and technical requirements stipulated in the specific legal metrology norms, and at the intervals stipulated by the metrological legislation in force.

Figure 2. Identification plate

3.48. (1) The dispenser and filling point must provide the possibility of being connected to the control system that will monitor and control the entire CNGV storage

and distribution station, including the priority control panel.

(2) It is recommended that the dispenser and filling point enable the sealing of

the hose and path between the CNGV storage facility and the transfer point to be checked before starting to refuel the vehicle.

(3) The dispenser shall not start if the remnant pressure in the storage cylinder set is lower than 40 bar.

3.49. The filler nozzle or filler gun can be of the following types: type A with dual

action and radial connection, type B with single action and radial connection, or type

C, which is a hybrid between the other two types and must consist of the following components:

a. a mechanism for quick and safe coupling, which can be firmly and safely connected to the vehicle cylinder;

b. a filling tube which acts upon the CNGV pipe by means of a casing for

fittings and related parts such as: springs, O-rings, etc.; c. at least one manually-activated fitting;

blue

18

d. a protective case made of plastic material treated against static electricity to

enable handling;

e. a threaded input connector.

The CNG pipe system

3.50. The CNG pipe system includes all the technological pipes of the CNGV storage and distribution station and must be made of materials that ensure compatibility with

the compressed natural gas, in accordance with the recommendations issued by standards SR EN ISO 11114 -1, SR EN ISO 11114-2, SR EN ISO 11114-3 and SR

EN ISO 11114-4.

3.51. (1) The CNGV pipe system must meet the essential safety requirements for

pressurised equipment that are recommended in harmonised standards SR EN 13480 (all parts) Metallic industrial piping for operation at 25 MPa (250 bar) in the

temperature range from minus 40 °C to plus 65 °C, for pipes laid above the ground, and from minus 20 °C to plus 65 °C, for buried or covered pipes.

(2) It is recommended that the material used for the pipes is stainless steel of

at least type 18-8, and that the wall of the pipe is extra-thick.

(3) Pipes made of plastic material (PE, PP, PA), galvanised pipe, aluminium or copper alloys that contain more than 70% Cu shall not be used.

(4) The incoming-supply pipes of the station, which are working at a pressure ≤ 1.6 MPa (16bar), must be made in accordance with the recommendations of SR EN

12007-1, SR EN 12007-2 and SR EN 12007-3 Gas supply systems. Pipelines for

maximum operating pressure up to and including 16 bar (Parts 1,2,3).

3.52. (1) The CNGV pipe system must be supported by a support system that ensures its stability under operating loads and special seismic loads.

(2) It is recommended that the pipe supports are placed no more than 600 mm apart.

(3) The CNGV technological pipe system must be positioned to prevent

collision with the vehicles coming in to refuel; otherwise, it must be protected

appropriately. (4) It is recommended that a CNGV technological pipe system mounted above

ground is installed inside a protected and reinforced technological trench, which is covered with a grate or perforated sheet metal and permits drainage of rain water.

3.53. (1) The CNGV pipe system must allow all operating manoeuvres, as well as

maintenance and repair activities.

(2) The total number of joints must be reduced to the minimum number that is

technically possible. (3) Before carrying out leak tightness or pressure tests, all joints must be

checked using non-destructive methods.

3.54. The CNGV pipe system must be protected against corrosion by means of a

resistant covering layer, whilst buried pipes must be protected using a cathodic protection procedure suitable for the conditions of the location with the connections

electrically isolated from the gas pipe, or be made of stainless steel and placed on an adequate sand bed.

19

3.55. The pipes, fittings, armatures, special connectors, excess flow fittings and

safety valves must be marked according to their class of operating pressure and meet the essential safety requirements specific for pressurised equipment.

System for filling cylinders and tubes with CNG for transportation to the

daughter CNGV distribution station

3.56. The system for filling cylinders and tubes with CNG for transportation to the

daughter station consists of a set of cylinders or tubes, whose capacity is established

depending on the design capacity of the daughter station.

3.57. The system for filling cylinders and tubes with CNGV for transportation to the daughter station can consist of a set of cylinders or tubes mounted directly on the

vehicle responsible for carrying it to the daughter station, or a set of cylinders that needs to be handled in order to be transported.

3.58. The system for filling cylinders or tubes with CNGV for transportation to the

daughter station must be connected to a priority control panel.

Acoustic cabin

3.59. (1) The acoustic cabin is a metallic structure designed to support and place

the equipment of the NG compression system and the cascade of CNGV storage cylinder or tube sets, which must ensure stability and protection of the operators and

location in the event of fire and explosion; it must be built to bear special loads

caused by such stresses, and can be of one of the following types:

a. modular structure made of pre-assembled concrete, made in accordance with the installation conditions within the location;

b. container-type modular structure adapted to the size of the compression and storage system;

c. structure with a protection canopy.

(2) The acoustic cabin must be designed to ensure protection against the

weather conditions and loads resulting from mechanical shocks and pressure, as well as unforeseen acts or acts of terrorism, and must comply with the recommendations

of SR EN 13501-1, SR EN 13501-2 and SR EN 13501-3 Fire classification of construction products and building elements. (Parts 1, 2, 3).

(3) An acoustic cabin with a container-type modular structure shall be made

of non-combustible materials from at least Class A2s1d0 of reaction to fire, whilst the

thermal and sound insulation, as well as waterproofing insulation must be made of materials from at least Class Bs2d1 of reaction to fire.

(4) The acoustic cabin is the cabin used for sound insulation of the NG compression system equipment, which must ensure a maximum noise level 1 m

away from the exterior of the sound protection structure of the NG compression

system, in accordance with the recommendations of SR EN ISO 3740 Acoustics.

Determination of sound power levels of noise sources. Guidelines for the use of basic standards, SR EN ISO 11689 Acoustics. Procedure for the comparison of

noise-emission data for machinery and equipment and SR EN ISO 10052 Acoustics. Field measurements of airborne and impact sound insulation and of service

equipment sound. Survey method.

(5) All equipment of the CNGV storage and distribution station must be

provided with protection against electrical discharges (lightning) in accordance with

20

the recommendations issued in standards SR EN 62305-1, SR EN 62305-2, SR EN

62305-3 and SR EN 62305-4 Protection against lightning (Parts 1,2,3,4).

Foundations

3.60. The foundations of the equipment located within the CNGV storage and distribution station must be designed to ensure preservation, development and

protection of water resources, protection against any form of pollution or modification

of the characteristics of water resources as well as to restore the quality of surface

and underground water, in accordance with the recommendations regarding: - the design of direct foundation structures;

- the principles, requirements and methods for geotechnical research of foundation ground;

- the anti-seismic design of constructions.

They must be made of reinforced concrete of the appropriate quality for the loads

specific to operating conditions, soil characteristics of the location and seismic area, in order to ensure operational stability and integrity of the station.

3.61. The materials used to make the foundations must meet the quality conditions required by using eurocodes for constructions, as well as the recommendations of SR

EN 13501-1, SR EN 13501-2 and SR EN 13501-3 Fire classification of construction

products and building elements. (Parts 1,2,3).

Station building (cabin)

3.62. (1) The building (cabin) of a CNGV storage and distribution station shall be

designed in accordance with the national regulations on design, manufacture, operation, decommissioning and post-use specific to the dispensing of fuel to

vehicles.

(2) An exception is the cabin of an independent CNGV storage and

distribution station, which can be designed and made of non-combustible materials, as well as construction materials, provided that its fire performance fits within the

accepted A2 and B classes of reaction to fire and on the basis of the recommendations of SR EN 13501-1, SR EN 13501-2 and SR EN 13501-3 Fire

classification of construction products and building elements. (Parts 1,2,3).

CNGV leak detection, warning and fire extinguishing systems

3.63. (1) The CNGV storage and distribution station must be equipped with compressed natural gas leak detectors, calibrated in accordance with Article 3.17

and/or SR EN 50073 Guide for selection, installation, use and maintenance of apparatus for the detection and measurement of combustible gases and oxygen.

(2) The operating instructions must contain a description of all possible

scenarios that could lead to accidental CNG leaks, as well as the prevention

procedures.

3.64. Fire extinguishing installations for the CNG storage and distribution station

must be designed, manufactured and used in accordance with the provisions of the fire safety regulations in force, the general fire protection norms and the present

technical norm.

21

3.65. The building (cabin) of the CNGV storage and distribution station shall be

designed to ensure fire safety in accordance with the Normative document for fire safety in constructions and the recommendations of SR EN 1994-1-1 and SR EN

1994-1-2 Eurocode 4: Design of composite steel and concrete structures (Parts 1-1, 1-2) and SR EN 1996-1-1 and SR EN 1996-1-2 Eurocode 6: Design of masonry

structures (Parts 1-2), respectively; it shall be equipped with technical means for the

prevention and extinguishing of fire, in accordance with the provisions of the fire

safety regulations in force, supplemented by the national general norms on fire protection, and must allow access for the emergency services and evacuation of

people via emergency routes.

3.66. CNGV storage and distribution stations located on sites where there is a public

water network and a pillar fire hydrant (SR EN 14384 Pillar fire hydrants) or an

underground fire hydrant (SR EN 14339 Underground fire hydrants) located less than

50 m away shall be equipped with the necessary water routing accessories, consisting of discharge hoses, discharge pipes that also operate with a spray jet, pipe

wrenches, etc. For underground fire hydrants, a portable valve hydrant (SR 697 Fire-extinguishing equipment. Portable valve hydrant) or portable hydrant (SR 698

Fire-extinguishing equipment. Portable hydrant) shall also be provided, together with

a hydrant wrench (STAS 696:1980 Fire-extinguishing equipment. Underground

hydrant wrench).

3.67. A CNGV storage and distribution station located on sites where there is a

public water network and the nearest fire hydrant is more than 50 m away shall be equipped with an installation of pillar or underground external hydrants, as well as the

necessary water routing accessories mentioned in Point 3.66.

3.68. For sites that do not have a public water network or external fire hydrants, but

where there is a natural source of water (lake, pond, river, etc.) within 400 m from a mixed or independent station that can ensure the necessary intervention capacity of 5

l/s for at least 3 hours, the owner is obliged to build a ramp for supplying mobile or fixed fire-fighting pumps.

3.69. (a) A CNGV storage and distribution station located on sites without a public

water or external fire hydrant network must have access to a minimum fire water

reserve ensured from outside for 30 minutes, at a capacity of at least 5 l/s; (b) The water reserve can be ensured directly from basins, tanks or natural

sources by means of mobile or fixed intervention pumps, and the necessary water routing accessories must be provided in accordance with Article 3.69 and 3.70.

3.70. (1) A CNGV storage and distribution station must be equipped with at least

the following means of first-line intervention:

- a 9 kg portable powder fire extinguisher for each CNGV dispenser and compressor, as well as for each CNGV storage cylinder set and the filling cascade;

- additionally, a 100 kg mobile powder fire extinguisher; - a 5 kg carbon dioxide fire extinguisher for the electrical and automation installations

of the station.

22

(2) The equipment of the daughter station is identical to and specific to the

type of station described in Article 2.1. (3) The reference standard for mobile fire extinguisher with a nominal load of

100 kg is SR EN 1866-1 Mobile fire extinguishers. Part 1: Characteristics, performance and test methods, whilst the reference standard for portable and carbon

dioxide fire extinguishers is SR EN 3 (All parts) Portable fire extinguishers and EC

Directive 97/23/EEC and/or equivalent regulations of the Member States of the

European Union or Turkey or EFTA States that are party to the Agreement on the European Economic Area, which are lawfully manufactured and/or sold in

accordance with the normative specifications in force in these countries and have equivalent fire extinguishing performances.

3.71. It is prohibited to cross the CNGV storage and distribution station, as well as

any potentially explosive areas located within water, gas, power, heating or sewage

network stations, other than those belonging to the CNGV station.

3.72. Utility installations (electrical, sanitary, heating, ventilation and air conditioning,

gas, automation, etc.) shall be designed, manufactured and operated in accordance with the specific regulations in force.

4. Technical requirements for designing equipment for CNGV storage and

distribution stations

4.1. (1) The following aspects must be taken into consideration when designing a CNGV storage and distribution station:

a. the possibility of supplying natural gas from the NG pipeline, or by delivering gas cylinders from the mother CNGV storage and distribution station;

b. the required capacity and pressure must be ensured in the pipeline from which

the station is supplied, to ensure operation of the compression system of the CNGV

storage and distribution station, in accordance with the type of CNGV storage and distribution station stipulated in Article 2.1;

c. average estimate of the CNGV within the location; d. the CNGV peak load at the location during a working day;

e. the electrical power available at the location, as well as the obligation of the

power supplier to ensure the minimum power necessary to operate the CNGV

storage and distribution station under safe conditions. f. the minimum power load needed for mixed stations using multiple fuels;

g. the type of motor conversion kits and the way in which these are connected to the dispenser of the CNGV storage and distribution station;

h. the speed at which CNGV vehicle cylinders are filled;

i. the degree of modularisation of the CNGV storage and distribution components;

j. The highest reliability rate considered to pose minimum risks when shutting down the CNGV storage and distribution station for maintenance or repairs.

(2) During the design stage, the provisions of SR EN 13617-1 Petrol filling stations. Part 1: Safety requirements for construction and performance of metering

pumps, dispensers and remote pumping units can be used.

23

4.2. (1) The pressurised equipment used in a CNGV storage and distribution

station, as well as all pressurised and safety accessories, must meet the design, manufacture, testing, marking and labelling requirements that are considered to be

necessary to ensure safety of the pressurised equipment;

(2) The measuring instruments that are part of the pressurised equipment

shall be checked in accordance with the provisions of the national metrological legislation in force;

(3) All of the provisions shall apply to both new stations, as well as stations which have undergone modifications such as those given below:

a. increase of the allowable overpressure;

b. extension of the station by adding further groups of structures;

c. replacement, modification and extension of the components, of different degrees of quality, which do not meet the technical requirements or do not belong to

the same verified pressure class; d. change of location.

4.3. (1) When designing pressurised equipment, all of the elements that

guarantee safety of the equipment for its entire lifespan set by the manufacturer must

be taken into consideration.

(2) In addition, the following factors must also be taken into consideration: a. internal/external pressure (maximum allowable operating pressure of 35

MPa (350 bar), corresponding to a maximum allowable operating temperature of 65 °C for CNGV, and an exterior pressure of 0.1 MPa (1 bar), respectively;

b. operating temperature and ambient temperature (a maximum allowable

operating temperature of plus 65 °C and a minimum allowable operating temperature

equal to minus 40 °C; c. static pressure and mass of contents under operating and testing

conditions; d. loads generated by the impact conditions due to traffic and extraordinary

loads due to earthquakes, wind and snow;

e. reaction forces and moments of reaction created by the supporting

elements, retaining elements, pipes, etc.; f. corresponding safety coefficients, for the prevention of all types of

damages; g. the possibility of different loads occurring simultaneously;

h. corrosion and erosion, fatigue, etc.;

i. the possibility that unstable fluids may decompose.

(3) CNGV storage and distribution stations must be equipped with safety accessories or safety measurement, control and adjustment accessories that can

prevent a non-permitted excess operating pressure in the equipment components, pipes or storage cylinders within the station.

(4) CNGV storage and distribution stations must be surrounded by security

fencing, to prevent access of foreign persons and acts of terrorism; they must be

marked with warning signs bearing the risk and danger phrases, in accordance with the CNGV technical safety sheet.

4.4. When choosing pressure regulating accessories, the engineer must take into account the following:

a. state of the fluid contained: gas or liquid; b. classification of the fluid contained: group 1 or group 2;

24

c. maximum allowable pressure;

d. volume in litres or nominal diameter, as applicable.

4.5. The working methods and techniques used in the design and manufacturing

stages must meet the essential safety requirements, using the following techniques: a. intensification: which involves reducing the inventory of dangerous

materials to a level that allows the dangers to be reduced; b. substitution: which involves replacing a dangerous material with a safer

one; c. attenuation: which involves using a dangerous material under less

dangerous conditions; d. limitation: which refers to primarily altering the design of the equipment or

changing the reaction conditions by adding protection equipment; e. simplification: which considers that, to reduce the number of major

accidents caused by operating errors, simpler systems are easier to use than

complex systems; f. avoidance of destructive effects: which considers that systems can be

designed to reduce the likelihood that events caused by damages in other locations

or “domino" effects may occur; g. avoidance of incorrect assembly: which stipulates that critical equipment

within the infrastructure should be designed to make incorrect assembly difficult or

impossible.

4.6. It is recommended that the design is carried out in accordance with the

harmonised standards:

a. SR EN 13445 (all parts) Unfired Pressure Vessels;

b. SR EN 13480 (all parts) Metallic industrial piping,

which ensures compliance with the essential safety requirements in accordance with

Annexes ZA and ZB of the standards (also see Annex ZA of the present norm). (2) Other design standards and codes can be used, as long as the engineer

can prove that the essential safety requirements for pressurised equipment are met,

and that there is a correlation between the codes and the essential safety

requirements.

4.7. In addition, the execution plan must also specify:

a. the measures taken to ensure safe handling/use and operation; b. the appropriate means for emptying and airing the pressurised equipment;

c. the measures relating to filling/emptying operations, including the measures for

the metrological calibration of storage cylinders;

d. the measures taken to ensure protection against exceeding the allowable operating limits for the pressurised equipment;

e. the measures taken to ensure compliance with the essential requirements for the design of assemblies used in CNGV storage and distribution stations.

4.8. (1) Special measures must be taken to ensure protection against fire or

explosion; all equipment as well as the joints between pipes and fittings must be

made so that they are, by design and from a technical point of view, leak-tight during operation for a prolonged period of time and that no CNGV leaks occur during normal

operation.

25

An exception are small quantities of CNGV released when the dispenser hoses are

disconnected from the refuelled vehicle.

(2) When designing and manufacturing piping, it must be made sure that

there is no risk of the flanges, connexions or hoses becoming overstressed due to a

non-permitted free movement or the production of excessively large forces, which

must be compensated adequately by using support, reinforcement, retaining, aligning and pre-tensioning elements.

4.9. Special attention must be paid to the possibility that certain events may occur due to turbulence and vortices in the profile of CNGV flow through the suction pipes

of the compressors, as well as to the possibility that fatigue may occur due to

vibrations in the pipeline.

4.10. It is necessary in its design to mark all branch points, indicating the fluid contained within; relief valves must be fitted between the branches equipped with

shut-off fittings, in order to absorb the thermal expansion of CNGV during warm periods.

4.11. The design shall stipulate the obligation to protect CNGV pressurised

equipment against corrosion; all buried equipment shall be provided with suitable

cathodic protection.

4.12. (1) The following standards are recommended when choosing the type of

cathodic protection (with current injection or sacrificial anodes): a. SR EN 12954 – Cathodic protection of buried or immersed structures. General

principles and application for pipelines; b. SR EN 13636 – Cathodic protection of buried metallic tanks and related

piping; c. SR EN 12499 – Internal cathodic protection of metallic structures;

d. SR EN ISO 12944 (all parts) – Paints and varnishes – Corrosion protection of steel structures by protective paint systems.

4.13. Establishing the requirements for the materials (granulation, aggregates,

position of ground water, etc.) used for embedding or coating buried and/or covered

metallic pipes and their positioning must be taken into consideration when ensuring stability and establishing other loads acting on the pipes.

4.14. (1) Buried pipes must not intersect other pipe routes or electrical cables. (2) The discharge and pressure relief pipes must not intersect the airing

pipes. If all three pipes are grouped together, the operation of the components should

not be affected.

(3) Joining pipes located in areas with different pressure steps must be avoided; however, when these pipes are joined, the maximum possible pressure of

the collecting pipe must not exceed the maximum operating pressure allowed in the area with the lowest pressure step.

Materials

4.15. (1) The station equipment and materials used for its manufacture must

ensure safety for the entire lifespan guaranteed by the manufacturer, and must be operational under the normal conditions set by the manufacturer for operating and

26

keeping it in operation, as well as the stresses that stations are subjected to during

operation. (2) The materials used to manufacture the equipment in CNGV filling stations

must: a. be compatible with the composition of the CNGV that is used;

b. have characteristics that are compatible with the operating conditions and

are predictable for all testing conditions;

c. be sufficiently ductile and hard; d. prevent cracking under stress;

e. not be significantly affected by ageing; f. be resistant to corrosion or, alternatively, be protected against corrosion by

appropriate coatings;

g. be the right ones for the pressure and temperature conditions, as well as

their variations; h. comply with the recommendations of SR EN 13501 (all parts) – Fire

classification of construction products and building elements; i. not produce dangerous electrostatic charges during operation.

4.16. (1) It is recommended that the metallic materials used to manufacture

pressurised equipment comply with harmonised standards SR EN 13480 -2 Metallic

industrial piping – Part 2. Materials and SR EN 13445 -2 Unfired Pressure Vessels – Part 2. Materials, as well as the requirements of the European Agreement concerning

the International Carriage of Dangerous Goods by Road (ADR) in force. (2) Flexible and metallic hoses must be made of materials that are resistant to

corrosion and the action of compressed natural gas, as well as the most severe

pressure conditions during a breaking/rupture test, which must be performed at 4

times the maximum operating pressure, in low temperature conditions.

4.17. All metallic materials must hold inspection certificates in accordance with SR

EN 10204 Metallic products – Types of inspection documents.

4.18. Other materials can also be used, as long as the tests carried out for the

replacement materials are consistently comparable to the design requirements.

4.19. The manufacturer of metallic materials used to manufacture pressurised

equipment and safety accessories shall guarantee the rupture energy KV or KCV resilience at the minimum allowable working temperature for the equipment.

4.20. Sealing materials must be compatible with CNGV, comply with the requirements of SR EN 682 Elastomeric Seals. Materials requirements for seals used

in pipes and fittings carrying gas and hydrocarbon fluids, and have documents to

certify quality.

4.21. (1) When choosing materials for the other components of CNGV storage and distribution stations, the specific working conditions, as well as any additional and

accidental stresses must be taken into consideration, whilst the components must be accompanied by a Declaration of Conformity or product technical certificate.

(2) Glass windows with a surface area smaller than 0.12 m2 must be made of

safety or multi-layered glass with a thickness of at least 4 mm, whilst glass windows

with the a surface area larger than 0.12 m2 and those that are illuminated from the inside must be made of safety or multi-layered glass with a thickness of at least 4.5

mm.

27

4.22. (1) When designing the compression system, the environmental conditions at

the location where the compressor is installed must be taken into consideration: ambient temperature, atmospheric humidity, air flow and quality of the cooling air, as

well as the power of the installation.

(2) Appropriate staged cooling shall be ensured in places where the ambient

temperature is high.

4.23. When choosing the compression system, the design must:

a. eliminate or reduce risks as much as possible, by ensuring high levels of safety;

b. adopt the protective measures necessary for the risks that could not be

eliminated;

c. inform users about any remaining risks due to incomplete efficacy of the protective measures adopted, indicate whether special training is required and, if

necessary, specify whether personal protective equipment should be used.

4.24. When designing the compression system, the essential safety requirements for

industrial machines must be complied with.

4.25. (1) Each compression system must be equipped with a control device that

enables it to be shut-down completely and safely. (2) Activation of the control systems must not pose additional risks.

(3) The emergency disconnection of the station must not be cancelled by resetting the emergency button.

4.26. Pressure relief/equalising dampeners (pulsation or hydraulic equalising

dampeners) located in the compressor suction/discharge system and between the

stages must ensure compression without pulsation/vibration at the compression ratios required between the stages and at the relief (discharge-suction) pressures

that will be viewed on the control panel for each stage of the compressor.

4.27. Any overpressure that exceeds the values stipulated in the technical

documentation must be relieved via the safety valves that are mounted at each

compression stage.

4.28. Connection with the priority panel must be ensured using a compressor parameter control system.

4.29. The control system has a series of functions that must be ensured by means of alarms, protections and process control systems.

4.30. By design, the safety of the system must refer to:

a. assessing the intrinsic safety conditions, which identify with reducing and

limiting dangers as much as possible; b. preventing, limiting and/or reducing the escalation of any adjacent events

(“domino” effects); c. ensuring the safety of occupied buildings located within the site and at the

system location;

d. controlling the access of unauthorised personnel;

e. enabling access of the emergency services; f. providing facilities that enable rapid communication with the emergency

services.

28

4.31. (1) Typical alarms of the compression system must refer to:

a. high suction pressure; b. low suction pressure;

a. high discharge pressure; c. high level of vibration;

d. high temperature upon discharge; e. low pressure of the lubricating oil;

f. activation of the emergency shut-down button; g. gas leaks.

(2) Additional, optional, but very useful alarms must be for:

a. high temperature between the compression stages (for all stages);

b. high/low pressure between the compression stages.

4.32. CNGV leak detection must refer to:

a. human perception of the signals emitted and an increase in the risk of the detection system or transmission system operating incorrectly;

b. the objectives of the detection system;

c. the types of detectors and maintenance of the detectors, including

unsupervised maintenance procedures; d. management of the detection system and, implicitly, identification of other

sources that could contribute to major accidents or the occurrence of dangers: not knowing the areas of maximum risk and where the detectors should be installed, the

absence of detectors or presence of unsuitable detectors in the areas of maximum

risk, detectors that are incorrectly positioned or installed at the system location, low

level of maintenance and control of the detection system, too much confidence in inefficient detectors and detectors that are unable to reset so that the detection

process can be resumed; e. alarms, safety and protection devices that are unable to operate upon

command;

f. leaks that cannot be detected.

4.33. The delimitation of danger areas is closely connected to the degree of release and the release output generated by the release source during normal operation.

4.34. (1) The essential requirement for controlling the dispersion of CNGV releases must be natural ventilation of the area that poses an explosive hazard.

(2) When designing the ventilation system, the recommendations of SR EN

14986 Design of fans working in potentially explosive atmospheres must be complied

with.

4.35. Natural ventilation depends on where the source of release is located; it is

characterised by the geographical and meteorological conditions specific to the location, and must be sufficient to ensure dispersion of the entire explosive

atmosphere that may form in the area. For natural ventilation, it is important to know

the predominant wind direction at all times, which must be identified by visible means.

4.36. (1) The efficacy of ventilation in controlling the dispersion and persistence of an explosive atmosphere, characterised by the degree of ventilation (strong, medium

or weak), must, under specific conditions, modify the classification of dangerous areas.

29

(2) For natural ventilation, air holes must be located at the lowest and the

highest levels of the structure that must be ventilated, with direct access to the open air.

(3) The free surface area of each air hole must cover 0.5% of the total surface area of the space that needs to be ventilated.

(4) Mechanical ventilation must be regulated so that the air in the space that needs to be ventilated is safely discharged at least twice an hour, to prevent a

dangerous and explosive atmosphere from forming. (5) A ventilation system automatically activated by the leak detection system

must be installed in the storage areas, to ensure that CNGV concentrations higher

than 20% of the LEL do not accumulate, triggering the emergency shut-down.

(6) When designing flame arresters, the recommendations of SR EN 12874 Flame arresters. Performance requirements, test methods and limits for use must be

complied with.

4.37. Turning on the compressor must be ensured by installing protective relays

that would shut down the electric motor should overloading occur due to hydraulic,

mechanical, electrical or automation disturbances.

4.38. Operational disturbances must be signalled via an alarm system that must lead to the station equipment being shut down.

4.39. (1) CNGV storage and distribution stations must be equipped with leak detection systems calibrated for CNGV, which are provided with the possibility of

emitting a sound alarm (horn, ringer, etc.) when 10% of the lower explosive limit

(LEL) is reached, with the station being shut down when 20% of the LEL is reached,

and the supply from the natural gas distribution/supply and/or transport system being blocked. The response time of the leak detection system must be less than or equal

to 20 seconds, whilst the recovery time must not exceed 30 seconds. (2) The CNGV leak monitoring system must be connected to the monitoring

and control system for the entire CNGV storage and distribution station, including the

priority control panel.

4.40. (1) The foundations of the compression systems must be designed for appropriate loads and seismic loads, by the provision of anti-seismic dampeners.

(2) Floor surfaces that pose the risk of explosion must be fitted with coverings that do not allow sparks and electrostatic charges to occur, whose superficial

resistance must not exceed a value of 108Ω, in accordance with the

recommendations of SR EN 1081 Resilient floor coverings. Determination of the

electrical resistance or SR EN 61340-4-1 Electrostatics. Part 4-1: Standard test methods for specific applications. Electrical resistance of floor coverings and installed

floors.

4.41. Compression systems operating in areas with a high degree of seismicity must

be equipped with anti-seismic fittings which would automatically close the

technological flow when an earthquake begins.

Classification of potentially explosive areas

4.42. Hazardous areas within CNGV storage and distribution stations shall be

classified, and the protective measures taken therein shall be classified in accordance with:

30

a. The essential safety requirements for protection equipment and systems

designed to be used in potentially explosive atmospheres; b. The harmonised standards corresponding to equipment and systems used in a

potentially explosive atmosphere; c. The recommendations of SR EN 60079-10 – Electrical apparatus for explosive

gas atmospheres. - Part 10: Classification of dangerous areas; d. The recommendations of SR EN 1127-1 Explosive atmospheres. Explosion

prevention and protection. Part 1: Basic concepts and methodology.

4.43. (1) Potentially explosive areas are defined as being areas exposed to the risk of explosion, in which a dangerous explosive atmosphere may form. An area in

which the explosive atmosphere forms in quantities for which it is not necessary to take special protective measures shall not be considered to be an area exposed to an

explosion hazard.

(2) Areas exposed to an explosion hazard are sub-divided based on the

frequency at which the dangerous explosive atmosphere is formed, as well as its duration, as follows:

1. zone 0, which corresponds to an area where a gaseous explosive

atmosphere is present all the time or for long periods of time under normal operating conditions of the system (more than 1 000 hours/year); this extends to:

a. the interior of NG compression cylinders of the compressors;

b. the interior of CNGV storage and transport cylinders and tubes belonging

to the storage and distribution station;

c. the interior of the CNGV dispenser meter body;

2. zone 1, which corresponds to an area where a gaseous explosive

atmosphere is likely to form under normal operating conditions of the system (between 10-1 000 hours/year); this extends to:

a. the interior of the casing for mechanical protection and sound insulation

of the NG compression system equipment;

b. the interior of the distribution pump casing; c. the space around the safety valves;

d. the transfer (supply) point of the system used to fill cylinders with CNGV in order to be transported to the daughter station;

e. the area around the ventilation duct of the casing that provides

mechanical protection and sound insulation of the NG compression system

equipment; f. the area covered by the dispenser hose when unwound;

g. the area corresponding to the vehicle transfer (refuelling) point; h. a radial area of 1.5 m around the axis of safety valves;

3. zone 2, which corresponds to an area where it is not possible for a

gaseous explosive atmosphere to form under the normal operating conditions of the

system; if, however, such an atmosphere does occur, it is possible that this will only

last for a short period of time (less than 10 hours/year) and extend to (see Figure A2.3):

a. the space around the CNGV storage and distribution station, for a radius of

2 m; b. the space around the storage cylinders or tubes, for a radius of 2 m;

c. the area around the dispenser or filling point, for a radius of 3 m;

d. the area around the transport vehicle.

31

4.44. (1) The delimitation of the areas that pose an explosion hazard for the

equipment of a CNGV storage and distribution station is presented in Annex No 2. (2) All of electrical and non-electrical equipment and its components that are

to be used in areas with a potentially explosive atmosphere must be designed and manufactured in accordance with good engineering practices and the

recommendations of SR EN 1127-1 Explosive atmospheres. Explosion prevention

and protection. Part 1: Basic concepts and methodology.

(3) Non-electrical equipment used in areas with a potentially explosive atmosphere must comply with the recommendations of SR EN 13463-1

Non-electrical equipment for use in potentially explosive atmospheres. Part 1: Basic method and requirements.

4.45. (1) CNGV storage and distribution stations must be dealt with, where

applicable, in accordance with the provisions of the national legislation on drawing up

a safety report. (2) The following aspects must be taken into consideration when drawing

up the safety report: a. shutting-down or discontinuing the natural gas supply of CNGV storage and

distribution stations;

b. non-conformity of the quality of the natural gas supplied;

c. over- or under- odorisation of the natural gas supplied; d. major faults of the gas devices or fittings;

e. accidents or other emergencies that could occur or threaten to occur; f. civil emergencies;

g. any other danger that could affect normal operation;

h. detailed procedures for safe isolation of the station and application of safety

management.

5. Building of CNGV storage and distribution stations

5.1. CNGV storage and distribution stations must be allocated sufficient ground

surface area to ensure both the working area and the maintenance and repair area.

5.2. A CNGV storage and distribution station must be suitably protected against collisions with vehicles and the access of unauthorised persons, with special attention

being paid to the storage and distribution area.

5.3. (1) A CNGV storage and distribution station must bear appropriate signs

regarding the access and evacuation of vehicles and people, as well as any

no-access areas.

(2) The CNGV pipe system must be visible and permanently marked with the direction in which the working fluid circulates.

(3) All pipes and fittings must be firmly secured to prevent disconnection during normal operation.

(4) Components that are located on different foundations, which can move

independently, must be connected by means of flexible elements.

(5) Pipes that are laid in underground channels must be equipped with ventilation and drainage that prevent any potential explosive mixtures during normal

operation and are easily accessible for visual inspection.

32

5.4. The equipment of the CNGV storage and distribution station will usually be

installed in the open air or in designated structures where all necessary ventilation measures will be taken.

5.5. (1) Electrical and non-electrical equipment, as well the components of CNGV storage and distribution stations must have an Ex construction, or must be placed in

areas that do not have an explosive atmosphere (safety areas).

(2) Appropriate measures must be taken to provide electrical grounding and

ensure continuity of the ground connections of the equipment and technological pipes of the CNGV storage and distribution station, which will eliminate the risk of

electrostatic discharges.

(3) The resistance at the ground connection measuring point must be less

than 0.1Ω (1 V voltage drop). (4) The CNGV storage and distribution station must be equipped with a

suitable lightning arrester system. (5) To prevent occurrence of electrical discharges between the filler nozzle

and the filler hose, the materials chosen must ensure the resistance between the

nozzle and the ground is less than 106Ω.

5.6. Electrical and non-electrical equipment, as well as the components of a CNGV storage and distribution station must meet the minimum requirements for explosion

Group IIA and temperature Class T3, in accordance with the recommendations of SR EN 60079-0 Electrical apparatus for explosive gas atmospheres. Part 0: General

requirements and SR EN 13463-1 Non-electrical equipment for use in potentially

explosive atmospheres. Part 1: Basic method and requirements.

5.7. When the electrical equipment and cables are located in dangerous areas, they must correspond to the types of protection specified in SR EN 60079-0, taking into

account the area where they are installed.

5.8. Any pressure safety device must be adjusted to a pressure that does not

exceed 1.1 times the maximum allowable pressure for the pressurised equipment

that they protect.

5.9. (1) All pressure gauges must have a reading scale at least equal to 1.2 times the maximum operating pressure.

(2) All pressure gauges within a CNGV storage and distribution station must be marked with the same units of measurement.

5.10. Acceptance of the works so that CNGV storage and distribution stations can be

set into operation, shall be carried out in accordance with the acceptance regulations

for installation works for machinery, equipment and technological systems, for setting production facilities into operation, and for construction works and their related

systems; the required acceptance documents shall be drawn up.

Pressure resistance testing and leak tightness testing

5.11. The components of a CNGV storage and distribution station, as well as the

station itself, must be subjected to a leak tightness test and a pressure resistance

test, in accordance with the essential safety requirements specific for pressurised equipment, or the manufacturer’s instructions.

33

5.12. Before performing these tests, all documents that certify the tests performed on

the CNGV storage and distribution station equipment by the manufacturer, the documents for the materials used during manufacture, any reports and other

documents drawn up during manufacture, both for the mechanical equipment and the electrical, automation and safety components within the station and especially within

areas with an explosion hazard, must be checked.

5.13. The pressure resistance test shall be performed with the safety valves blocked.

5.14. The leak tightness test shall be performed for normal operating conditions.

5.15. The pressure resistance test must be carried out for all station components and

technological pipes, at a test pressure that is 1.43 times the maximum allowable operating pressure, making sure that all pressure gauges that operate at pressures

lower than the test pressure are isolated (turned off).

5.16. (1) The pressure shall be gradually increased, in steps that are 10% of the

test pressure; the pressure must be recorded during testing.

(2) The duration of the test must be at least 1 hour.

(3) The test shall be considered to be successful if the pressure did not

undergo any variations during testing.

5.17. The system must be filled with an appropriate test fluid, which must be, for

example, a compatible liquid hydrocarbon or glycol.

5.18. When performing these tests, all measures shall be taken to drain all low points

(also see Figure A2.3).

5.19. (1) The leak tightness test shall be carried out pneumatically, preferably using

nitrogen, with a dew point of at least 40 °C.

(2) Leaks can also be identified, if possible, using foam producing solutions, in

accordance with SR EN 14291 Foam producing solutions for leak detection on gas installations.

5.20. During this test, all points that are susceptible to compressed natural gas leaks during normal operation must be checked.

5.21. The tests shall be considered to be successful if no test fluid leaks occur during

testing.

5.22. Once these tests have been performed, the necessary precautions shall be taken for purging the station in accordance with Articles 8.9 - 8.12, at discharge

speeds that do not affect the equipment and the pipes.

5.23. (1) If leaks occur during testing, then their cause shall be found, the required

remedies shall be made and the test shall be repeated after preliminary

depressurisation.

(2) No remedies shall be made under pressure.

5.24. (1) The periodicity of the pressure testing of pressurised equipment, for the

entire lifespan guaranteed by the manufacturer, must comply with the provisions of the European Agreement concerning the International Carriage of Dangerous Goods

34

by Road (A.D.R.) and UN-ECE Regulation R110 on transportable pressurised

equipment. (2) It is prohibited to carry out the pressure resistance test without a special

technical appraisal. (3) It is prohibited to exceed the lifespan recommended by the manufacturer of

the pressurised equipment in any way.

(4) Requalification of pressurised cylinders that bear the European mark Π(pi)

must be assessed depending on the maximum number of operating cycles – filling/emptying with CNGV.

(5). Cylinders whose maximum number of operating cycles is higher than or equal to 10 000 cycles shall be subjected to a pressure resistance test using acoustic

emission, in accordance with SR EN ISO 16148 Gas cylinders. Refillable seamless

steel gas cylinders. Acoustic emission testing (AT) for periodic inspection, whilst the

terms used in the testing procedure must comply with SR EN 1330-9 Non-destructive testing. Terminology. Part 9: Terms used in acoustic emission testing. Cylinders that

fit the rejection criteria shall be decommissioned and replaced with new, suitable cylinders.

5.25. (1) When performing a pressure resistance test, all precautions must be

taken for working at high pressures, by:

a. adequate protection for pressurised equipment and pipes; b. conformity of the pressure gauges with the test pressure;

c. improving the security of the location to traffic in the area; d. resistance of materials to sudden rupture;

e. prevention of local cooling whilst filling and emptying the equipment and

pipes;

f. conditions for permanent monitoring of the test. (2) Whilst the tests are carried out, warning signs shall be put up in all

directions, bearing the text: “WARNING – STATION UNDERGOING HIGH PRESSURE TESTING”.

6. Safety distances

6. 1. (1) The minimum safety distance for the fitting that delimits the delivery point

shall be established depending on the NG operating output of the station, in accordance with the data given in Figure A2.2. The manual shut-down fitting

supplements the automatic shut-down fitting and the anti-seismic fitting (if

necessary).

(2) The safety distances between the CNGV storage and distribution station components are given in Table 6.1.

Table 6.1. Safety distances recommended between the station components1

Storage and

decompressio

n unit

Priority

panel CNGV dispenser

Storage and

compression unit 2 m 3 m

Priority panel 2 m 4 m CNGV dispenser 3 m 4 m

1The boundary of the station shall be established by complying with the distances given in Figure

A2.2.

35

(3) The safety distance from the compression system to the filling point

collector must be a minimum of 30 metres (Figure 3b).

Figure 3. Measuring the minimum safety distances

6.2. (1) The minimum safety distances between the CNGV storage and distribution station equipment and facilities located outside the station are given in Table 6.2 and

are valid for all types of mother-daughter stations that the present technical norm

refers to, in accordance with Article 3.5(3).

(2) The safety distance between the vehicle transfer point and the dispenser is presented in Figure 3a.

(3) In all situations, including for compact modular stations, the distances shall be measured from the boundary of the equipment.

Table 6.2. Minimum safety distances between the station equipment and other facilities

Storage and compression unit

Priority panel CNGV dispenser

Above-ground storage areas for flammable or combustible liquids, or flammable or oxidising gases

5 m 5 m 7.5 m

Above-ground pipes for flammable or combustible liquids, or flammable or oxidising gases

5 m 5 m 7.5 m

Filling point collector

Transfer point

Lmin = 3 m Lmin = 3 m

Compression system

36

Underground storage areas for flammable or oxidising gases, or flammable or combustible liquids, including buried pipes

2

7.5 m 7.5 m 12.5 m

Suction system of the ventilation or air conditioning equipment or air compressors

7.5 m 7.5 m 5 m

Boundary of the adjacent property on which construction work is to be carried out

3 m 3 m 3 m

Civil public buildings, buildings used for production and/or storage, or other public or recreational places, regardless of the number of people

3

15 m 15 m 15 m

Motorways, all types of national roads, public roads or alleys

5 m 5 m 6 m

Railways for fast or medium traffic, excluding underground railway lines (underground trains)

15 m 15 m 15 m

Low voltage power lines4 7.5 m 7.5 m 7.5 m

High voltage power lines, as above 15 m 15 m 15 m Distribution pumps for other fuels (petrol, diesel, methanol, etc.)

6 m 6 m 3 m

LPG distribution pumps 7.5 m 7.5 m 5 m LPG cylinder storage areas 7.5 m 7.5 m 7.5 m Smoking or any sources of ignition are not permitted at a certain distance from any components of the CNGV storage and distribution station

1

≤ 10 m ≤ 10 m ≤ 10 m

1 the following are considered to be sources of ignition: open flame, sparks of any type (static, electrical, mechanical,

etc.), hot and incandescent surfaces, spontaneous sources, possible chemical and physico-chemical reactions, and radiating heat; 2 shall not be installed above the locations of any type of underground storage;

3 for buildings classified as posing a high and very high risk of fire, the distances shall be increased by 50%;

4 the distances shall be measured in accordance with the technical regulations in force.

7. Carrying out activities in CNGV storage and distribution stations

7.1. Commercial activities carried out by individuals/economic operators within CNGV

storage and distribution stations, periodic technical inspections, modifications to the

structure of the station and decommissioning of pressurised equipment within the

CNGV storage and distribution station shall be authorised in accordance with the

specific legislation.

7.2. Metrological verifications of measuring instruments within the storage and

distribution station subject to legal metrological control are compulsory and shall be

carried out in accordance with the metrological and technical requirements stipulated

in the specific legal metrology norms, and at the maximum intervals of time stipulated

in the official national list of measuring instruments subject to legal metrological

control in force.

7.3. CNGV storage and distribution stations shall only be operated by vehicle

compressed natural gas supply operators trained by professional training services

providers on the basis of programmes especially designed for this activity.

37

8. Operation, maintenance and repair of CNGV storage and distribution stations

8.1. (1) Normal operation of CNGV storage and distribution stations is the appropriate operation that fulfils the objectives that each installation/equipment is

responsible for, depending on its specific role within the structure of the station. Normal operation of the CNGV storage and distribution station includes:

a. Operation according to the design, including the measures required in

order to ensure the good operation of the installation/equipment, such as taking

samples, including storage along with the filling, transfer (for daughter stations) and emptying stages;

b. Acceptance, commissioning and setting the installation into operation; c. Operation during testing periods; d. Repair, inspection, maintenance and cleaning/purging works; e. All situations of temporary non-operation.

(2) During normal operation, an incident/accident means any voluntary or involuntary deviation from the appropriate method of operation, which has technical

significance. (3) Normal operating procedures must contain: drawings, diagrams,

instructions and all the information required for the operations to be performed

correctly. (4) The gas meter and dispenser must be subjected to legal metrological

control in accordance with the provisions of the metrological legislation in force.

8.2. (1) The dirtiness of the filters on the main NG flow must be permanently monitored; this must be organisationally or technically ensured by means of devices

that display the maximum pressure drop measured.

(2) The filters and separators must be equipped with rapid shut-off devices,

constructed so that they can be opened and emptied during operation without posing any imminent danger.

8.3. Under normal filling conditions, the dew point of CNGV must be lower than minus 20 °C, for which the NG drying systems provided must ensure that cryohydrates

cannot form and normal operation is not affected.

8.4. (1) The drawing up of maintenance procedures must be based on:

a. the need to attenuate major accidents or dangers; b. human factors;

c. the qualification level of the work force; d. principles of good maintainability;

e. understanding of the malfunction and maintainability rate;

f. criteria for recognising mistakes and effective performance;

g. factors for assessing procedures; h. actual maintenance plan;

i. drawing up the maintenance policy and strategy; j. drawing up the schedule and list for maintenance works;

k. the list of spare parts necessary for maintenance works.

(2) The list of inspection operations performed on CNGV storage and distribution

stations is given in Annex 3; certification of the fact that these inspections have been carried out shall be recorded in specific inspection reports.

38

8.5. The defect analysis must include all subject fields that could contribute to a

complete mechanical, electrical, electronic, structural, chemical and metallurgical appraisal of the incident/accident and must be carried out by specialised personnel.

8.6. The analysis of defects must include:

a. the way in which the defect occurred;

b. the effects of: fatigue, rupture, corrosion, erosion, wear and tear, quality of

welded joints, materials that are not suitable for use, manufacturing defects, human errors, risks posed by the work place, external causes, etc.

8.7. The stages that must be completed in order to carry out CNGV storage and distribution operations shall apply to both independent and mixed mother or daughter

stations.

8.8. Together with the manager of the CNGV storage and distribution station, the

vehicle compressed natural gas supply operator (code 932002 in the Nomenclator for the Classification of Economic Activities) shall be responsible for taking all necessary

measures in order to ensure safe operation of the station, as follows: a. he or she is responsible for performing operating manoeuvres under safe

conditions in all situations required by the condition of the station;

b. if accidental CNGV leaks occur, he or she shall perform the special

operations stipulated in the procedure relating to the situation; c. he or she is responsible for managing the CNGV and to only allow it to be

dispensed to vehicles or recreational boats that are homologated to travel on national roads or water, in accordance with the national legislation;

d. he or she shall record in the reports record all of incidents that occur during

their shift, as well as the condition in which the CNGV storage and distribution station

was received and handed over to the pressurised fluid bottler on the next shift.

8.9. Before filling the cylinders in the station cylinder set cascade with CNGV, it is

compulsory to dry and eliminate all air from the cylinders; this shall be carried out by: a. correctly purging the air from the recipients;

b. inertisation of the station equipment, using nitrogen or helium.

8.10. Correct purging of the CNGV storage station equipment to eliminate air shall be

repeated until the air has been completely eliminated.

8.11. It is prohibited to purge the CNGV at the maximum operating pressure.

8.12. The operation of CNGV storage and distribution stations consists of performing the following operations:

a. filling storage cylinders up to a pressure of 5 MPa (50 bar) for the first

filling;

b. checking the leak tightness of all related joints and opening all fittings (safety cocks and remote controlled cock) to check the leak tightness of the other

joints; c. continue filling the cylinders up to the operating pressure, providing that

all joints are perfectly sealed; any possible leaks shall be remedied, followed by a

new leak tightness test. Filling up shall only be continued after all leaks have been

remedied; d. supplying electrical power to the system.

39

The operations are identical for all CNGV storage and distribution stations, and are

coordinated via the priority panel.

8.13. The evacuation of the air from the system is carried out using the compression

unit of the CNGV storage and distribution station and also includes its elements.

8.14. Once the air has been evacuated, inertisation of the station must be performed

using nitrogen or helium.

8.15. Air should be reintroduced in the station only after evacuating the system and

then re-purging it.

8.16. The CNGV cylinders or tubes that are part of the cylinder set cascade of the

CNGV storage and distribution station shall only be filled by the vehicle compressed natural gas supply operator.

8.17. Cylinder or tube sets shall be transported to daughter stations only by road

vehicles that are equipped in accordance with the requirements of the European

Agreement concerning the International Carriage of Dangerous Goods by Road (ADR) and are homologated in accordance with the national legislation.

8.18. The vehicles used to transport cylinder or tube sets to daughter stations shall be parked within the safety distances from the compressor, with the engine turned

off, in gear and secured with both the foot brake and the blocks provided as

equipment.

8.19. To pressurise the CNGV, the pressurised fluid bottler shall connect the cylinder set to the compression system in accordance with the specific operating procedures,

but only after: a. connecting the vehicle to the ground and preparing the fire prevention and

extinguishing equipment provided;

b. checking that there are no sources of danger in the filling area;

c. analysing the possibility of quickly removing the vehicle from the area in the event of danger;

d. delimiting the access area for unauthorised persons; e. checking the fittings mounted on the transportable cylinder set;

f. checking the equipment mounted on the vehicle;

g. connecting the CNGV filling hoses to the transportable cylinder set;

h. checking the leak tightness of all connections; i. an explosimeter must be used whenever it is considered necessary, to check

for any potential CNGV leaks at the critical points.

8.20. The cylinder set pressurisation procedure must be permanently supervised by

the pressurised fluid bottler.

8.21. (1) CNGV shall only be dispensed to road vehicles that are homologated for

CNGV and have this information entered on their identity card in order to be allowed to travel on Romanian public roads, monitoring the following:

a. correct positioning of the vehicle at the designated place; b. the special identification label applied to the vehicle (Figure 4);

c. the position of the vehicle cylinder filler nozzle, checking whether a leak-tight

coupling between the fitting on the vehicle cylinders and the type of filler gun used for

40

the dispenser hose is possible (it is recommended to use filler guns that are equipped

with EURO-type coupling systems); if coupling is not leak-tight, refuelling shall not take place;

d. identifying, if possible, if the markings on the cylinders are authentic and correspond to those entered on the registration certificate;

e. connecting the vehicle to the ground using a special cable provided with a

clip; the ground connection shall be made by checking that the contact between the

clip and the ground terminal is perfect; f. the dispenser filler gun shall be connected to the vehicle cylinder fitting in

accordance with the stages indicated on the special plate attached to the dispenser;

Figure 4 Identification label

g. after starting the dispenser, the operation of its meter must be monitored, at

the same time as the pressure level in the cylinders; it is not permitted to exceed the maximum pressurisation level;

h. after the required quantity of CNGV has been dispensed, the filler gun shall be disconnected depending on the type of filler gun installed on the dispenser; the

dispenser shall be turned off and the filler gun shall be disconnected following the

stages indicated on the special plate attached to the dispenser.

8.22. Should any technical issues occur, pressurised fluid bottlers shall take measures so that, in the event of accidental CNGV leakage, the following operations

can be performed, with priority being given to saving human lives: a. if the on-site detection equipment (sensor cell or portable

detector-explosimeter) detects any leaks, all operations shall be discontinued;

b. the immediate supervisor and the police shall be informed, as well as the

fire brigade and the ambulance services (if necessary); c. attempts shall be made to limit the leaks from spreading;

d. warning signs shall be installed to prohibit the access of people to the area (all people shall be evacuated to an area opposite the direction of the wind), and all

sources of flames shall be prohibited;

e. access to the area shall be prohibited to all vehicles, except for intervention

vehicles; f. the power supply to the area shall be cut off;

g. if a fire has started that cannot be put out, measures shall be taken to get it under control; a fire caused by CNGV leaks should not be put out, since its spreading

could cause fire or explosions that are harder to control in adjacent areas;

h. if CNGV leaks occur without causing a fire, effective measures shall be

taken to put out/turn off all sources of flames; i. the water cooling system (using either a continuous jet, which is applied to

the source of the leak, or spray) shall be turned on immediately.

Risk analysis of CNGV storage and distribution stations

41

8.23. An analysis of all possible risks must be drawn up as part of the design or

operating instructions, to provide possible malfunctioning scenarios prepared by documentation.

8.24. The risk assessment analysis of CNGV storage and distribution stations shall be carried out depending on the possible scenarios that could cause major CNGV

accidents.

8.25. The risk assessment methodology must be based on assessment criteria that

are determined by: a. static conditions: access routes, crossings in the transport, road and/or

railway network, warning systems, signal transmission units and malfunction detectors, bridges, tunnels, protection walls, high voltage lines and pillars,

construction elements that are needed to access the system and infrastructure –

railway stations, cabins, depots, etc.; b. dynamic conditions: maintenance, level of training of the personnel, training

modules, planning of the transport process, logistics, provisional processes and

control procedure; c. external conditions: population density alongside the location, presence of

industrial storage areas and the risk potential of the dangerous substances stored

therein, position of power installations, crossings of the pipe routes (water, gas,

heating), areas of conflict between two transport systems (parallel railway and road systems, crossings and level crossings, bridges, tunnels), weather influence (areas

with fog, rain intensity, snow, ice, the length of time with natural light, direction and intensity of the wind, etc).

8.26. The risk assessment shall be carried out by classifying the probability of events

occurring, as well as the severity or consequences of the event, in the matrix

associated to the risk relating to the activity carried out in a CNGV storage and distribution station.

8.27. (1) An estimation of the probability of events occurring, as well as their severity or consequences, is recommended in Table 8.1, whilst classification of the risk is

recommended in the risk assessment matrix given in Table 8.2.

Table 8.1. Classification of probability and severity/consequences

Probability

A Likely to happen straight away; (P>10-1

)

B Likely to happen in the near future: (10-1

> P >10-2

)

C Likely to happen over time (10-2

> P >10-3

)

D Likely to happen at some point (10-3

> P >10-6)

E Unlikely to happen (P ≤10-6

)

Severity/Consequences

Class I - Catastrophic Subject to events that could cause death or injuries with permanent disability, or severe damages to major systems, which lead to damages of more than 1 million EURO

42

Class II – Critical Subject to events that could cause severe injuries or professional illnesses, or major damages with a value between 200 000 and 1 million EURO

Class III - Moderate Subject to events that could cause minor injuries or professional illnesses, or major damages to property, with a value between 10 000 and 200 000 EURO

Class IV – Negligible Subject to events that may require first aid, as well as non-essential damages to property, which can be remedied at once and have a value between 2 000 and 10 000 EURO.

Table 8.2. Risk assessment matrix

Estimated probability Classes of severity/consequence

s A B C D E

I Very high high high Medium Low

II high high Medium Low Low

III Medium Medium Low Low Low

IV Low Low Low Low Low

8. 28. For dangerous situations in which the CNGV leaks stipulated in Table 8.3 have occurred, measures shall be taken to prohibit the access of any persons that

are not involved in intervention activities.

Table 8.3. Possible situations of CNGV leakage in CNGV

storage and distribution stations

Situation

Description of the CNGV leakage situations (from or due to)

1 Deterioration of the dispenser hose. Rapid leakage of CNGV through the hose, until the excess flow fitting is blocked

2 Leakage of the entire quantity through the transfer pipe due to the excess flow valve being faulty

3 CNGV leakage through the safety valve

4 CNGV leakage without causing a fire

5 Corrosion-induced CNGV leakage through a hole in the pressurised transfer pipe that goes to the dispenser

9. Provisions regarding safety and hygiene at work, as well as fire prevention

and fire fighting

9.1. The personnel responsible for operating the CNGV storage and distribution

station shall be employed, allocated and trained in accordance with the general

norms specific for safety at work, taking into account the specific emergency

situations and the general fire-fighting norms.

9.2. (1) Warning signs (made in accordance with SR ISO 3864-1 Graphical

symbols. Safety colours and safety signs. Part 1: Design principles for safety signs in workplaces and public areas, SR ISO 3864-2 Graphical symbols. Safety colours and

safety signs. Part 2: Design principles for product safety labels and SR ISO 3864-3

Graphical symbols. Safety colours and safety signs. Part 3: Design principles for

graphical symbols for use in safety signs) shall be installed within the stations and in the areas where the dispenser pump, compressors and cylinder or tube sets are

located, to warn about inflammable gas areas where it is compulsory to turn off the

43

engine during refuelling and switch off mobile phones, and where smoking and the

use of any sources of open flames are prohibited. (2) Vehicles shall access the refuelling point marked within the station at a

speed of 10 km/h, which shall appear on warning signs.

9.3. Only authorised personnel who have received appropriate professional

training and have skills and normal physical and neuropsychical abilities shall be

used to carry out works relating to the operation, maintenance and repair of the

installations of a CNGV storage and distribution station.

9.4. No individuals must be allowed to work if they are under the influence of

alcohol or drugs, are tired or in a physical and mental state that does not allow them to concentrate.

9.5. Connecting and disconnecting the filler gun to the vehicle cylinders, and filling

the vehicle cylinders, shall be carried out using suitable protective equipment.

9.6. The operator who supplies compressed natural gas to the vehicles located at the CNGV storage and distribution station shall permanently carry out the filling

operation for the CNGV pressurised storage cylinders installed on the vehicle.

9.7. When the station is in operation, it is prohibited:

a) to perform any work duties without wearing the protection and intervention

equipment (PIE) provided;

b) to force anyone to perform work duties without providing them with personal protective equipment suitable for their duties;

c) to wash the protection and intervention equipment (PIE), as well as the work and intervention equipment (WIE) with flammable products, both within and

outside the station;

d) to continue working with personal protective equipment contaminated with

CNGV purged in gaseous phase; e) to wear clothing made of synthetic materials, or which can be

electrostatically charged; f) to wear shoes with metallic accessories that may cause sparks; g) to set the station into operation without a final acceptance report signed by

the acceptance commission established by means of a decision of the undertaking

director; h) to start or operate the station without the protection and safety devices

stipulated in the documentation, or with the reservation of them being provided later on;

i) to allow vehicles to access the station area and park them when the

system is not operational, is on stand-by, or during unloading.

9.8. The vehicle compressed natural gas supply operator is not allowed to carry out works and operations that are outside of his or her area of responsibility:

a. to intervene within the station in order to carry out modifications or repairs (carrying out repairs falls under the competence of intervention teams who have been

specially trained for this purpose);

b. to set the station into operation after each shut-down, without the protection

and safety devices and measuring and control instruments with which it has been equipped, and to disassemble these instruments during operation;

c. to leave the workplace whilst vehicles are being refuelled;

44

d. to allow untrained drivers to refuel vehicles themselves;

e. to continue dispensing CNGV when defects occur to any of the station equipment;

f. to use makeshift heating devices, or heating devices with an open electrical resistor inside the station cabin;

g. to operate a faulty or makeshift electrical installation, or overload the circuits by using equipment with a rated power above the designed one;

h. to dispense CNGV to customers who breach the fire prevention rules or behave in an uncivilised manner inside the CNGV storage and distribution station.

9.9. The fire extinguishing installations of the CNGV storage and distribution

station must be designed, manufactured and operated in accordance with Article 3.63

– 3.70 of the present norm.

10. Decommissioning and post-use/relocation of CNGV storage and

distribution stations

10.1 The safe decommissioning of CNGV storage and distribution stations must be

carried out in compliance with the following preparatory measures:

a. to power down all electric equipment; b. to isolate the respective location using dismountable panels, in order to

prevent the access of vehicles and unauthorised persons; c. to display signs bearing the risk and danger phrases around the perimeter of

the location, in accordance with the technical regulations in force;

d. to disconnect the station from the NG distribution/supply and/or transport

system; e. to empty the CNGV storage and distribution station and ensure that the

interior atmosphere is inert and not dangerous for all equipment within the location; f. to provide the required technical means for fire-fighting, in accordance with a

procedure specific for this operation;

g. to train personnel using specific procedures and issue them with a work

permit.

10.2. The CNGV storage and distribution station shall be decommissioned on the

basis of specific procedures that are detailed and notified for each equipment disassembling operation.

10.3. The disassembled equipment or parts of equipment shall be removed from the

site.

10.4. Open fire and tools that could cause sparks upon impact are prohibited when disassembling the CNGV storage and distribution station.

10.5. The provisions of the legislation in force relating to monitoring the operational behaviour, in-line interventions and post-use of constructions, as well as relating to

the authorisation of any construction works must be complied with when demolishing

and disassembling above-ground buildings (structures).

10.6. (1) It is recommended that above-ground buildings (structures) are demolished and disassembled only after all recoverable and/or reusable elements

have been removed.

45

(2) The recoverable and/or reusable elements and materials shall be stored

or moved to well established places, where they do not interfere with carrying out the work.

10.7. Mechanical machinery can only be used under safe conditions, so that they do

not promote the occurrence of fire or deteriorate any installations or equipment that

has not been disassembled or evacuated.

10.8. Reconditioning/requalification of any disassembled elements that are intended

to be reused shall only be carried out in specialised workshops, ensuring that the designed parameters and safety conditions are met during their subsequent use and

taking into account the manufacturer’s recommendations regarding their lifespan.

10.9. Once the CNGV storage and distribution station has been decommissioned,

its owner shall take all necessary measures to rehabilitate the ground and repair the environment.

10.10. The post-use/relocation operations for CNGV storage and distribution stations shall be carried out in accordance with the specific rules and measures for this type

of works, which are stipulated in specific regulations.

10.11. Pressurised equipment must be relocated after a qualified assessment and

appropriate tests have been carried out.

11. Final provisions

11.1. CNGV storage and distribution stations that are to be set into operation after the date on which the present normative document comes into force shall be

operated in accordance with the present technical norm, on the basis of a licence and

authorisation for carrying out this activity obtained in accordance with the national

regulations.

11.2. The relevant legislative bibliography and the list of specific CNGV standards

are given in Annex No 1.

46

Annex No 1

Relevant legislation and list of CNGV-specific standards

1.1. Relevant legislation

1.1.1. European directives adopted by the Romanian legislation

EC Directive Adopted in the national

legislation by: Regarding:

73/23/EEC 93/68/EEC

Government Decision 457/2003, republished

(Official Gazette No 311/8 May 2007)

ensuring safety for users of low voltage electrical equipment

87/404/EEC 90/488/EEC

93/68/EEC

Government Decision 454/2003, republished

(Official Gazette No 538/8 August 2007)

Government Decision 1242/2004 amending Government Decision

454/2003 (Official Gazette No 751/18

August 2004)

establishing the conditions for placing simple pressurised recipients on the market

89/336/EEC 92/31/EEC 93/68/EEC (98/13/EC)

Government Decision 982/2007

(Official Gazette No 645/12 September 2007)

electromagnetic compatibility

98/37/EC 98/79/EC

Government Decision 1029/2008

(Official Gazette No 674/30 September 2008)

the conditions for placing machines on the market

90/384/EEC 93/68/EEC

Government Decision 617/2003, republished

(Official Gazette No 418/16 June 2003)

establishing the conditions for placing non-automatic weighing devices on the market and setting them into operation

90/396/EEC 93/68/EEC

Government Decision 453/2003

(Official Gazette No 489/9 June 2005)

establishing the conditions for placing apparatus that uses gaseous fuels on the market

94/9/EC

Government Decision 752/2004

(Official Gazette No 499/3 June 2004)

establishing the conditions for placing protective equipment and systems designed to be used in potentially explosive atmospheres on the market

97/23/EC

Government Decision 584/2004

(Official Gazette No 404/6 May 2004)

Government Decision 1168/2005 for the

modification and supplementation of

Government Decision 584/2004

(Official Gazette No 914/12 October 2005)

establishing the conditions for placing pressurised equipment on the market

99/36/EC Government Decision

941/2003 establishing the conditions for placing transportable pressurised equipment on the

47

(Official Gazette No 636/14 August 2003)

Government Decision 1941/2004

(Official Gazette No 1119/29 November 2004)

market and its repeated use

2001/95/EC

Law No 245/2004, republished

(Official Gazette No 360/9 May 2008)

general safety of products

89/106/EEC

Government Decision 622/2004, republished

(Official Gazette No 487/20 July 2007)

establishing the conditions for placing construction products on the market

93/465/EEC

Law No 608/2001, republished

(Official Gazette No 419/4 June 2008)

product conformity assessment

94/55/EC

Law No 122/2002 for the approval of Government

Ordinance 48/1999 (Official Gazette No 198/25

March 2002)

carriage of dangerous goods by road (the European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR.)

48

96/49/EC 67/548/EEC

MTCT Order 644/2005 (Official Gazette No 416/17 May

2005)

Government Emergency Ordinance 145/2008

(Official Gazette No 754/7 November 2008)

establishing rules for the carriage of dangerous goods by railway, regarding the classification, labelling and packaging of dangerous chemical substances and preparations

94/25/EC

Government Decision 2195/2004

(Official Gazette No 16/6 January 2005)

establishing the conditions for placing on the market and/or setting into operation recreational boats

89/686/EEC

Government Decision 115/2004

(Official Gazette No 166/26 February 2004)

establishing the essential safety requirements for personal protective equipment, and the conditions for placing them on the market

80/181/EEC 85/1/EEC

89/617/EEC 1999/103/EC

Government Decision 755/2004

(Official Gazette No 475/27 May 2004)

the approval of legal measurement units

89/106/EEC MTCT Order 620/2005

(Official Gazette No 399/11 May 2005)

the free circulation of construction products; with regard to the implementation and use of Eurocodes for constructions

2002/49/EC

Government Decision 321/2005, republished

(Official Gazette No 19/10 January 2008)

the assessment and management of ambient noise

2004/22/EC

Government Decision 264/2006

(Official Gazette No 264/29 March 2006)

establishing the conditions for placing measuring instruments on the market and setting them into operation

Government Decision 1425/2006

(Official Gazette No 882/30 October 2006)

for approval of the Methodological guidelines for applying the provisions of Law No 319/2006 on health and safety at work

MAI Order 163/2007

(Official Gazette No 216/29 March 2007)

for approval of the general fire protection norms

1.1.2. National legislation

Law No 351/2004, with its subsequent modifications

(Official Gazette No 337/18 May 2007)

Gas law

Government Emergency Ordinance 195/2005

(Official Gazette No 1196/30 December 2005)

regarding environmental protection

Law No 230/2003 (Official Gazette No 370/30 May 2003)

regarding homologation of road vehicles and issuing their identity book so that they can be allowed to use public roads in Romania

Law No 107/1996 (Official Gazette No 244/8 October 1996)

Water law

Law No 10/1995, with its subsequent modifications

(Official Gazette No 12/24 January 1995)

regarding quality in constructions

Law No 50/1991, republished (Official Gazette No 933/13 October 2004)

regarding the authorisation of construction works

Law No 64/2008 (Official Gazette No 240/27 March 2008)

regarding the safe operation of pressure vessels, lifting equipment and fuel-consuming devices

49

MTCT Order 1889/2004 (Official Gazette No 1167/9 December 2004)

regarding the approval of certain procedures for technical approval in constructions

Law No 166/2007 (Official Gazette No 406 of 18 June 2007)

for the approval of Government Ordinance No 25/2007 amending Government Ordinance No 20/1992 on metrological activities

Government Decision 762 of 16 July 2008 (Official Gazette No 566 of 28 July 2008)

for approval of the national strategy for preventing emergency situations

50

Government Decision 1425/2006 (Official Gazette No 882/30 October 2006)

for approval of the Methodological guidelines for applying the provisions of Law No 319/2006 on health and safety at work

MAI Order 163/2007 (Official Gazette No 216/29 March 2007)

for approval of the general fire protection norms

1.2. List of relevant standards

ISO 11119 -1, ISO 11119 -2 Gas cylinders of composite construction. Specification

and test methods;

ISO 11622 Gas cylinders. Conditions for filling gas cylinders; ISO 14469-3 Road vehicles. Compressed natural gas (CNG) refuelling connector.

Part 3: 25 MPa (250 bar) connector; ISO 15500 - Road vehicles - Compressed natural gas (CNG) fuel system

components;

ISO 19078 - Gas cylinders-Inspection of the cylinder installation, and requalification

of high pressure cylinders for the on-board storage of natural gas as a fuel for automotive vehicles;

ISO 9809 (all parts) Gas cylinders. Refillable seamless steel gas cylinders. Design, construction and testing;

ISO 5145 Cylinder valve outlets for gases and gas mixtures. Selection and

dimensioning

ISO 22434 Transportable gas cylinders. Inspection and maintenance of cylinder valves;

ISO 24431 Gas cylinders. Cylinders for compressed and liquefied gases (excluding acetylene). Inspection at time of filling;

ISO/TR 14600:2000 Gas cylinders. International quality conformance system. Basic

rules;

CENELEC report R044-001 Safety of Machinery - Guidance and recommendations for the avoidance of hazards due to static electricity;

SR EN 10204 Metallic products. Types of inspection documents; SR EN 1081 Resilient floor coverings. Determination of the electrical resistance; SR EN 1127-1 Explosive atmospheres. Explosion prevention and protection. Part 1:

Basic concepts and methodology; SR EN 12245 Transportable gas cylinders. Fully wrapped composite cylinders SR EN 12257 Transportable gas cylinders. Seamless, hoop-wrapped composite

cylinders; SR EN 12499 Internal cathodic protection of metallic structures;

SR EN 12874 Flame arresters. Performance requirements, test methods and limits

for use;

SR EN 12954 Cathodic protection of buried or immersed structures. General principles and application for pipelines; SR EN 13445 (all parts) Unfired Pressure Vessels; SR EN 13463 -1 Non-electrical equipment for use in potentially explosive

atmospheres. Part 1: Basic method and requirements;

SR EN 13480 (all parts) Metallic industrial piping;

SR EN 13501 (Parts 1,2,3) Fire classification of construction products and building elements;

SR EN 13617-1 Petrol filling stations. Part 1: Safety requirements for construction and performance of metering pumps, dispensers and remote pumping units; SR EN 13636 Cathodic protection of buried metallic tanks and related piping;

51

SR EN 13645 Installations and equipment for liquefied natural gas. Design of

onshore installations with a storage capacity between 5 and 200 t; SR EN 14382 Safety devices for gas pressure regulating stations and installations.

Gas safety shut-off devices for operating pressure up to 100 bar; SR EN 14291 Foaming solutions for detecting leaks on gas installations;

SR EN 15001-2 Gas infrastructure. Gas installation pipework with an operating

pressure greater than 0,5 bar for industrial installations and greater than 5 bar for

industrial and non-industrial installations. Part 2: Detailed functional requirements for commissioning, operation and maintenance; SR EN 1964 (all parts) 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; SR EN 60079-10 Electrical apparatus for explosive gas atmospheres. Part 10:

Classification of dangerous areas; SR EN 61340 -4-1 Electrostatics. Part 4-1: Standard test methods for specific

applications. Electrical resistance of floor coverings and installed floors; SR EN 682 Elastomeric Seals. Materials requirements for seals used in pipes and

fittings carrying gas and hydrocarbon fluids;

SR EN ISO 10297 Transportable gas cylinders. Cylinder valves. Specification and

type testing; SR EN ISO 11114-1 Transportable gas cylinders. Compatibility of cylinder and valve

materials with gas contents. Part 1: Metallic materials SR EN ISO 11114-2 Transportable gas cylinders. Compatibility of cylinder and valve

materials with gas contents. Part 2: Non-metallic materials SR EN ISO 11114-3 Transportable gas cylinders. Compatibility of cylinder and valve

materials with gas contents. Part 3: Autogenous ignition test in oxygen atmosphere

SR EN ISO 11114-4 Transportable gas cylinders. Compatibility of cylinder and valve

materials with gas contents. Part 4: Test methods for selecting metallic materials resistant to hydrogen embrittlement SR EN ISO 11117 Gas cylinders. Valve protection caps and valve guards. Design, construction and tests; SR EN ISO 11120 Gas cylinders. Refillable seamless steel tubes for compressed gas

transport, of water capacity between 150 l and 3 000 l. Design, construction and

testing; SR EN ISO 11439 Gas cylinders. High-pressure cylinders for the on-board storage of

natural gas used as a fuel for automotive vehicles; SR EN ISO 12944 (all parts) Paints and varnishes. Corrosion protection of steel

structures by protective paint systems; SR EN ISO 16148 Gas cylinders. Refillable seamless steel gas cylinders. Acoustic

emission testing (AT) for periodic inspection; SR 696 Fire-extinguishing equipment. Underground hydrant wrench;

52

SR 697 Fire-extinguishing equipment. Portable valve hydrant; SR 698 Fire-extinguishing equipment. Portable hydrant; SR 701 Fire-extinguishing equipment. Fixed connections. Dimensions; SR 702 Fire-extinguishing equipment. Inlet connections. Dimensions; SR 703 Fire-extinguishing equipment. Outlet connections. Dimensions; SR 705 Fire-extinguishing equipment. Blank connections. Dimensions;

53

Annex No 2 (informative)

Figure A2.1. Schematic diagram for a combined mother-daughter CNGV storage and distribution station

MOTHER STATION

DAUGHTER STATION

DISPENSER

COMPRESSOR

COMPRESSOR GAS METER

PRIORITY

CONTROL PANEL

TRANSPORT TRAILER

TRANSPORT TRAILER

CYLINDER FILLING

CYLINDER SET:

- LOW PRESSURE

- MEDIUM PRESSURE

- HIGH PRESSURE

PRIORITY

CONTROL PANEL

CYLINDER SET:

- LOW PRESSURE

- MEDIUM PRESSURE

- HIGH PRESSURE

NATURAL

GAS INLET

DISPENSER

54

Figure A.2.2 Delimitation of a CNGV storage and distribution station

Table A2.1 Informative characteristics of CNGV storage and distribution stations

Type of station 1 2 3 4 Capacity, in l 800 1 920 2 000 2 400

Number of cylinders 10 24 25 30

Volume, l/cylinder1 80 80 80 80

Volume of CNG stored at 300 bar

(250 bar), in m3

~ 279

(232)

670

(557)

697

(580)

837

(697)

Compression coefficient 0.86 0.86 0.86 0.86

Volume of CNG available at 300 bar

(250 bar), in m3

~ 97

(81)

~ 234

(195)

~ 244

(203)

~ 293

(244)

Operating factor ~ 35% ~ 35% ~ 35% ~ 35% Operating pressure, bar 300 300 300 300

Test pressure, bar 450 450 450 450 1For cylinders with a lower volume, the number shall be increased to ensure the capacity specified

By-pass fitting,

normally closed

Separation fitting for the delivery

point

Gas

meter

Standard operational flow rate in m

3/min

Minimum distance between the station boundary and the compression and storage unit, in m

< 3 5

3 – 5 6

5 - 10 7.5

10 - 15 10

15 - 20 12.5

Safety distances for the delivery point separation fitting

55

A2. 2. Zoning of the CNGV dispenser

Lighting in appropriate Ex

construction

Zone 1

GNCV

pump

Zone 1 around

the dispenser

Zone 1 around the

dispenser piston

Class 1, Zone 1

sound dispenser nozzle

56

Zone 1 around

the piston

Zone 1 around

the dispenser

Zone 1 around the

dispenser

Zone 1 around the dispenser

piston

57

A2. 3. Extension of zone 2 for the CNGV storage and distribution station equipment

Figure A2. 3 Detailed view of the installation of a horizontal storage cylinder

Zoning of the CNGV storage and distribution station equipment

(in accordance with IEC 60079)

Front view

Storage cylinders Compressor Dispenser

Stored cylinders

Stored cylinders

Compressor

Dispenser

Plan view

From the compressor to the

dispenser

Draining/purging

58

Annex No 3

A.3.1. Access options for CNGV storage and distribution stations

A3.1.1. CNGV storage and distribution stations can be accessed based on the

following options: - private access;

- public access.

Days and times of access depend on the working hours of the station.

A3.1.2. Private access: access is only permitted to the owner of the vehicle(s). Typically, the equipment is located at the main garage of the vehicle fleet holder,

often in an area that is secure and/or is provided with an access code or key for activating the dispenser. Access is prohibited to any other person or members of the

public who do not have the code.

For example: public services, those in transit and employees who work in the garage,

where supplying the public is prohibited.

A3.1.3. Public access:

(1) Limited public access to the refuelling facilities is limited by means of barriers, for example: the dispenser is located in a secure area that is open during

working hours and/or accessed using an access key approved in advance or a gate

code, for example requesting activation with a card or invoice code.

In general, customers who are in transit are denied access, and cash or credit card payments are not accepted. For example: public services or employees who

work with the vehicle fleet, where a limited number of guests who hold prior approval issued by the fleet management are authorised to use the filling equipment;

(2) Full access of the public:

In comparison to using the traditional retail procedures used in petrol and

diesel distribution stations, the access to CNGV dispensers placed in traditional locations for the distribution of petroleum products is open to everybody by using a

personal card, major credit card and/or cash (if the station accepts this method of payment; usually, this is not accepted) and CNGV dispensers that are installed

adjacent to a station with private-only access (supplying the vehicle fleet of a garage).

For example: the transit agency or employees who allow access of the public beyond

the garage fence. The examples can also include special CNGV distribution stations.

A3. 1. 4. Symbols for access groups: P – public, non-stop, restricted by an access code or invoice code, which is proof of advance payment and prior training;

PL – public, limited period, restricted by an access code or invoice code, which is

proof of advance payment and prior training;

PR – public, with restrictions, card, key or invoice code, with advance payment; PA – public, access using a code card, in accordance with a written agreement

concluded in advance; NA – private, no access;

N – private, only for buses;

G – authorised governmental personnel;

GA – governmental personnel with an access card;

59

NB - private, company buses;

U – special, unknown.

A3. 2. List of inspections that must be carried out in a

CNGV storage and distribution station Station component Inspection Passed NOT

passed Leaks

Condition of pressure gauges Gas supply pipeline Corrosion assessment

Signs for restricting access

No smoking signs

Signs for the automatic start-up button

Danger warning signs

Lighting system and switches

Mechanical and sound protection structure

Signs prohibiting the presence of foreign objects on site

Leak-tightness of safety valves

Leak-tightness of safety devices

Condition of pressure gauges

Ex protection of the electrical panel

Condition of the compressor pipe supports

Condition of the guards

Release pressure

Compressor

Gas leaks

Presence of leaks

Leak-tightness of safety valves

Condition of pressure gauges

Safety connections in the cylinder set and cascade

Condition of the fittings

Condition of the safety fencing

No smoking signs

Signs for restricting access

Corrosion assessment

Storage recipients-cylinders

Warning signs for the operating-test pressures

Presence of leaks

Visual examination

On-panel safety connections for the pressurised devices

On-panel safety connections for the pipes

Priority panel

Condition of the cover fasteners

Presence of leaks

Visual examination

On-panel safety connections for the pressurised devices

On-panel safety connections for the pipes

Emergency safety equipment

Condition of the cover fasteners

60

Presence of leaks

Condition of pressure gauges

Condition of the hoses and of the filler nozzle or filler gun

Final filling pressure

Leak-tightness of the meter

Dispenser

Safety connections of the dispenser pipes

Signs for restricting access Station site

No smoking signs

Presence of operating instructions General aspects

Training of the personnel

61

Annex ZA

(informative)

Table ZA. Relationship between this technical norm and the essential

requirements of Directive 97/23/EC

Essential requirement Description

Articles from norm NTGNCV-001:2008 that fully or partially cover the essential

safety requirements 1.1 Guaranteeing safety in accordance with the

manufacturer’s instructions 5.11

1. 2 Design principles 1.3, 4.5, 4.6, 4.17

2. 2 Design for adequate loads 4.2, 4.3

2. 2. 2 Design for loads corresponding to predictable use 3.10, 3.51, 4.2, 4.3, 4.15, 4.16, 4.20, 4.27

2.3 Handling and operating measures 4.37, 8.1

2. 4 Means of examination 5.15, 5.16, 5.24, 5.25

2. 5 Draining and airing equipment 4.15, 5.22, 8.8, 8.10-8.12, 8.14

2. 6 Corrosion or other forms of chemical degradation 4.11, 4.12, 4.18,

2. 7 Wear and tear 8.5

2. 8 Assembling operations 3.8, 3.11, 3.49

2. 9 Provisions for filling and emptying 3.9, 3.11, 3.32, 4.32,4.26, 5.23

2.10 Protection against exceeding the admissible pressure limits

3.8, 3.15, 3.37, 5.9

2. 11. 1 Adequate and reliable safety accessories 3.16, 3.18, 3.24, 3.31, 3.33

2. 11. 2 Pressure-limiting devices 3.15, 3.16, 3.39, 4,26, 5.9

2. 11. 3 Temperature-monitoring devices 3.42

2. 12 External fire 3. 64

3.1.2 non-dismountable joints 3.55

3. 1. 3 non-destructive tests (NDT) 5.11

3. 2 Final assessment 5.10, 5.12, Chapter 7 3.2.1 Final inspection 5.12

3.2.2 pressure resistance test 5.15 - 5.25

3.2.3 Inspection of safety devices 5.10, 5.12, 7.2, 8.1, 8.4

3.3 Marking and labelling 3.55

3.4 Operating instructions 8.1, 8.4, 8.8 - 8.12

4.1 Materials for pressurised parts 4.7, 4.16 - 4.22

4.2 Definition of the values required for calculation 3.9, 3.10, 3.16, 3.42, 3.51, 4.3

6 (a,b,d,e,g) Pipes 3.51, 3.52, 4.12

7 Specific quantitative requirements 5.12

62

Annex ZB

Table ZB. List of environmental inspections1

Life cycle stages

Procurement Production Operation End of life cycle All stages

Environmental

references

Raw materials and

energy

Sub-assemblies and

components

Production

Packaging

Operation

Maintenance and

repairs

Use of additional

products

Reusable materials

and energy recovery

Final provisions

Transport

Input (articles from the norm) Materials 2.3(1)

4.1 4.16 4.18 4.19

2.3(2) 3.7(4) 4.17 8.1

5.11 3.10 10.1 10.6 10.9

3.583.60

Water 3.61

Energy 3.25 3.6(1)

Ground 3.3

Output (articles from the norm) Air emissions 4.20

4.33

4.35 3.63

4.8 8.9 8.10

8.9 8.14

Discharges to water

3.60

Discharges on the ground

3.61 4.12

Waste

Noise, vibrations, radiation, heat

4.21 4.27

3.60 3.8(4) 3.20 3.60

Other relevant aspects (articles from the norm) Environmental risk due to accidents or non-intentional use

1.1 4.5 4.10 4.43

4.41 8.24 8.25

8.28

Client information 4.23 3.9

Comments: Article 1.2 Mutual recognition clause in accordance with EC Regulation No 764/2008: 1 In accordance with SR Guide ISO 64 or CEN Guide 4;

63

Relevant technical references (informative)

Joint Practical Guide of the European Parliament, the Council and the Commission

for persons involved in the drafting of legislation within the Community institutions;

Guide de rédaction des documents législatifs: Guide pratique commun du Parlement

européen, du Conseil et de la Commission à l'intention des personnes qui contribuent à la rédaction des textes législatifs au sein des institutions communautaires; ISO/CEI Directives (CEN/CENELEC adopted): - Part 1 Procedures for the technical work

- Part 2 Rules for the structure and drafting of International Standards;

NFPA 2 - Hydrogen Technologies Code;

NFPA 30 - Flammable and Combustible Liquids Code; NFPA 52 - Vehicular Fuel Systems Code;

NFPA 54 - National Fuel Gas Code; NFPA 55 - Standard for the Storage, Use, and Handling of Compressed Gases and

Cryogenic Fluids in Portable and Stationary Containers, Cylinders and Tanks;

NFPA 59A - Standard for the Production, Storage, and Handling of Liquefied Natural

Gas (LNG); NFPA 69 - Standard on Explosion Protection by Deflagration Venting;

NFPA 69 - Standard on Explosion Prevention Systems; NFPA 77 - Recommended Practice on Static Electricity;

NFPA 88A - Standard for Parking Structures;

NFPA 99C - Standard on Gas and Vacuum Systems;

NFPA 274 - Standard Test Method to Evaluate Fire Performance Characteristics of Pipe Insulation;

NFPA 306 - Standard for the Control of Gas Hazards on Vessels; NFPA 329 - Recommended Practice for Handling Releases of Flammable and

Combustible Liquids and Gases;

NFPA 385 - Standard for Tank Vehicles for Flammable and Combustible Liquids;

NFPA 497 - Recommended Practice for the Classification of Flammable Liquids, Gases or Vapors and of Hazardous (Classified) Locations for Electrical Installations

in Chemical Process Areas; NFPA 551 - Guide for the Evaluation of Fire Risk Assessments;

NFPA 921 - Guide for Fire and Explosion Investigations;

NFPA 1192 - Standard on Recreational Vehicles;

NFPA 5000 - Building Construction and Safety Code; FTA Report - Design Guidelines for Bus Transit Systems Using Liquefied Natural Gas

(LNG) as an Alternative Fuel (3/97); FTA Report - Compressed Natural Gas Safety in Transit Operations (10/95);

CSA B108-99 - Natural Gas Fuelling Stations Installation Code (Canada);

CSA B109-01 - Natural Gas for Vehicles Installation Code (Canada);

B51-97, Part 3 Requirements for CNG Refuelling Station Pressure Piping Systems and Ground Storage Vessels, (Canada);

ANSI NGV1-1994 (with 1997 and 1998 addenda) - Compressed Natural Gas Vehicle Fueling Connection Devices;

ANSI NGV2-2000 - Basic Requirements for Compressed Natural Gas Vehicle Fuel

Containers;

ANSI NGV3.1-1995 - Fuel System Components for Natural Gas Powered Vehicles; ANSI NGV4.1/CSA 12.5 -1999 - NGV - CNG vehicular fuel dispensing systems;

ANSI NGV4.2/CSA 12.52 -1999 - Hoses for NGVs and Dispensing Systems;

64

ANSI NGV4.4/CSA 12.54 -1999 - Breakaway Devices for Natural Gas Dispensing

Hoses and Systems; ANSI NGV4.8/CSA 12.8 -2002 - Natural Gas Vehicle Fueling Station Reciprocating

Compressor Guidelines; 49 CFR 178. 56 - Specification 4AA - CNG cylinders for fueling stations

NMSPU - Project KT 11 - Measurement, approval and verification of CNG

Dispensers, UK;

OIML R 137-1: Gas meters; OIML R 139: Compressed gaseous fuel measuring systems for vehicles; OIML R 140: Measuring systems for gaseous fuel; DOT-FTA-MA-26-7021-96-1 - Design Guidelines for Bus Transit Systems Using

Compressed Natural Gas as an Alternative Fuel, USA;

SAE J1616 Recommended Practice for Compressed Natural Gas Vehicle Fuel

Composition; SAE J2406 CNG Powered Medium and Heavy Duty Trucks;

SAE J2645 Liquefied Natural Gas (LNG) Vehicle Metering and Dispensing Systems - Truck and Bus;

UN-ECE R110 – Regulation No 110 of the United Nations Economic Commission for

Europe (UN-ECE) – Uniform provisions regarding the homologation of: I. Components specific to vehicles that use compressed natural gas (CNG) in their propulsion system;

II. Vehicles with regard to the installation of components that are specific to a type homologated for the use of compressed natural gas (CNG) in their propulsion

system; CONVENTION ON ROAD SIGNS AND SIGNALS (DONE IN VIENNA ON 8

NOVEMBER 1968); EUROPEAN AGREEMENT SUPPLEMENTING THE

CONVENTION ON ROAD SIGNS AND SIGNALS OPENED FOR SIGNATURE AT VIENNA ON 8 NOVEMBER 1968 (DONE IN GENEVA ON 1 MAY 1971);

Institute of Petroleum - Electrical installation of facilities for the storage and dispensing of LPG and CNG automotive fuels at vehicle refuelling stations; Institute

of Petroleum - IP 15 Code: Area Classification Code for Installations Handling

Flammable Fluids, Part 15; ENARGAS - NAG 419 - Parking and garages. Difficulties and accidents. Instructions for CNG filling (Argentina); ENARGAS - NAG 402 - Vehicles for bulk CNG transport; ENARGAS - NAG 406 - Transport system for CNG containers modules;

ENARGAS - NAG 416 - Minimum technical and safety Standards and Specifications

for on-board CNG fuel system installation and testing;

ENARGAS - NAG 418 - Regulations for CNG Filling Stations; ENARGAS - NAG 441 - Compression equipment for compressed natural gas filling

stations; TDG - G 304 02 (Czech Republic) - Refuelling CNG stations for motor cars;

DOT - Fuel Motor Vehicle Security Standard - FMVSS 303 Fuel system integrity of

CNGVs;

DOT - FMVSS 304 CNG Fuel Containers ONU-Conseille Economique et social-CE-Comite de transport interieur-Report

TRANS/WP - 1/100; DVGW - German Code of Practice G 260/I;

DVGW - Einspruchsfrist - technische Regel - Arbeitblatt G 651 - 2007;

NFPA 505 - Fire Safety Standard for Powered Industrial Trucks Including Type

Designations, Areas of Use, Conversions, Maintenance, and Operation;

65

Document -AS/NZS 2430.3.2:2004 - Classification of hazardous areas-Part 3.2:

Examples of area classification—Vehicle workshops, vehicle parking, fuel dispensing stations and aircraft hangars; REQUEST FOR PROPOSALS - California City of Commerce LNG/LCNG Fueling Station Design-Build Proposal;

NGV Refueling Systems: Types of stations and access options - Advance Fuel

Systems, USA; HSE Information sheet: Advice on gas detection strategies for HVAC duct inlets, No 5/2008, UK; Combustible Gas Monitoring System Guidelines, Sanitation District of LA, Industrial Waste Section, USA;