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AS 50922009
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AS 50922009
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This Australian Standard was prepared by Committee AG-009, Natural Gas Vehicle
Refuelling Stations. It was approved on behalf of the Council of Standards Australia on
13 August 2009.
This Standard was published on 1 October 2009.
Standards Australia wishes to acknowledge the participation of the expert individuals that
contributed to the development of this Standard through their representation on the
Committee and through the public comment period.
Australian Standards are living documents that reflect progress in science, technology and
systems. To maintain their currency, all Standards are periodically reviewed, and new editions
are published. Between editions, amendments may be issued.
Standards may also be withdrawn. It is important that readers assure themselves they are
using a current Standard, which should include any amendments that may have been
published since the Standard was published.
Detailed information about Australian Standards, drafts, amendments and new projects can
be found by visiting www.standards.org.au
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Australian Standard
Originated as AG 5041987.
Previous edition AG 9011996.
Revised and redesignated as AS 50922009.
COPYRIGHT
Standards Australia
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher.
Published by Standards Australia GPO Box 476, Sydney, NSW 2001, Australia
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AS 50922009
PREFACE
This Standard was prepared by the Standards Australia Committee, AG-009, Natural Gas
Vehicle Refuelling Stations, to supersede AG 9011996, Code of Practice for NGV
Refuelling Stations. It retains the same format and much of the previous text but with
technical and editorial amendments reflecting changes to Standards and regulations that
have occurred since AG 901 was last comprehensively reviewed.
The objective of the Standard is to provide manufacturers, designers, regulatory authorities,
testing laboratories, installers and similar organizations with minimum uniform
requirements for the safety, installation, performance and operation of CNG refuelling
stations.
The minimum requirements set out in this Standard are to be read in conjunction withbut
do not take precedence overany Statutory Regulations that may apply. In its preparation
consideration has been given to
(a)
(b)
(c)
(d)
(e)
The terms normative and informative have been used in this Standard to define the
application of the Appendix to which they apply. A normative Appendix is an integral
part of a Standard whereas an informative Appendix is only for information and guidance.
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Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
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3
AS 50922009
CONTENTS
Page
SECTION 3 INSTALLATIONS
3.1 PLANNING PERMISSION AND LICENCES.......................................................... 15
3.2 LOCATION, SECURITY AND PHYSICAL PROTECTION OF EQUIPMENT ...... 15
3.3 REFUELLING STATION ELEMENTS.................................................................... 18
3.4 INLET GAS SUPPLY EQUIPMENT........................................................................ 19
3.5 GAS COMPRESSION EQUIPMENT ....................................................................... 19
3.6 COMPRESSED GAS STORAGE SYSTEMS ........................................................... 20
3.7 DISPENSERS/FILL POSTS...................................................................................... 20
3.8 HIGH PRESSURE DISCHARGE SYSTEM ............................................................. 21
3.9 SAFETY AND CONTROL SYSTEMS..................................................................... 23
3.10 POWER AND CONTROL ELECTRICAL SYSTEMS ............................................. 24
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APPENDICES
A
REGULATORY AGENCY INFORMATION ........................................................... 33
B
TYPICAL LAYOUT OF MOBILE STORAGE UNITS ........................................... 36
C
REFUELLING INSTRUCTIONS AND PROCEDURES .......................................... 37
D
CHECKLIST FOR PUTTING THE STATION INTO SERVICE AND ANNUAL
SAFETY INSPECTIONS OF REFUELLING STATIONS ....................................... 38
E
HOT WORK PERMIT............................................................................................... 40
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AS 50922009
STANDARDS AUSTRALIA
Australian Standard
SECT ION
SCOPE
AND
GENERA L
1.1 SCOPE
This Standard specifies requirements for the design, construction, operation and
maintenance of compressed natural gas (CNG) refuelling stations, which can be one of the
following:
(a)
fast fill, where vehicles are filled in a period of minutes, analogous to liquid
refuelling;
(b)
time fill, where one or (in most cases) a number of vehicles are filled simultaneously
over a period of some hours; or
(c)
It does not cover equipment sizing and refuelling performance (the latter to be agreed
between the purchaser and station constructor to suit the particular requirements of each
station).
This Standard does not cover the requirements for the following:
(i)
(ii)
NOTES:
1
Appendix D contains a checklist that provides guidance on the aspects of the station that
should be checked prior to putting the station into service and during annual safety
inspections.
To the extent this Standard provides, in addition to minimum requirements, guidance in areas
relating to the design and installation of CNG refuelling stations, such guidance should not be
regarded as a design specification or an instruction manual.
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AS
AG 807
Approval requirements for natural gas flexible hose and hose assemblies for
pressures above 2.6 MPa
1349
1530
1530.4
1674
1674.1
1725
1851
2030
2030.1
Gas cylinders
Part 1: General requirements
www.standards.org.au
Standards Australia
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AS 50922009
AS
2441
2444
2473
2473.1
2832
2832.1
3814
4041
Pressure piping
4332
4343
4564
5601
Gas installations
AS/NZS
1850
3000
3788
60079
Explosive atmospheres
60079.10.1 Part 10.1: Classification
of
areasExplosive
gas
atmospheres
(IEC 60079-10-1, Ed. 1.0:2008 MOD)
60079.17 Part 17: Electrical installations inspection and maintenance (IEC 60079-17,
Ed. 4.0:2007 MOD)
ISO
11439
14469
Gas cylindersHigh pressure cylinders for the on-board storage of natural gas
as a fuel for automotive vehicles
Road vehiclesCompressed natural gas (CNG) refuelling connector
ANSI
ANSI/IAS Basic Requirements for Compressed Natural Gas Vehicle (NGV) Fuel
NGV 2
Containers
CSA
CSA B51
1.3 DEFINITIONS
Acceptable to, and meeting the prescribed standards of, the Technical Regulator (see
Clause 1.3.22).
1.3.2 Authority
Regulatory authority having jurisdiction or such authority as delegated (see also Technical
Regulator).
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AS 50922009
Group of cylinders or pressure vessels connected together, which may or may not be
connected into separate banks (i.e. sections), and complying with the requirements of this
Standard.
1.3.5 Dispenser/fill post
A unit for filling compressed natural gas into CNG cylinders, which may or may not
incorporate metering.
1.3.6 Fire Resistance Level (FRL)
The rating of the ability of an element of building construction to fulfil its required load
bearing function, integrity and thermal insulation in a standard fire resistance test as
determined in accordance with AS 1530.4 for
(a)
structural adequacy;
(b)
integrity; and
(c)
insulation.
A source of energy sufficient to ignite a flammable atmosphere that may include a naked
flame, exposed incandescent material, an electrical welding arc, a mechanical or static
spark and electrical or mechanical equipment not suitable for use in a hazardous location.
NOTE: For the purposes of this Standard, a motor vehicle entering a hazardous area associated
with any part of a refuelling station is not regarded as an ignition source.
A quarter turn manual valve capable of being locked off but not locked on, in order to
isolate all equipment downstream of the compressed gas storage system (see Clause 1.3.4).
1.3.10 Mobile gas storage
Multiple cylinders or pressure vessels permanently mounted on a special carriage and used
for the transportation of CNG to other refuelling stations.
1.3.11 Non-return valve
The internal pressure to that a pressure containing component is subjected under normal
operating conditions.
1.3.13 Pressure
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AS 50922009
A dwelling, place of worship, public building, school or college, child care facility,
hospital, theatre or any building or open area in which persons are accustomed to
assemble, whether within or outside the property boundary of the station.
(b)
A factory, workshop, office, store, warehouse, shop or building where people are
employed that is outside the property boundary of the station.
(c)
(d)
Any storage facility for dangerous goods that is outside the property boundary of the
station.
Any place, other than private property, open to the public and including a street or road.
Parking areas for commercial and public buildings are not considered public places.
1.3.16 Refuelling connector
Device that permits the safe, quick connection and disconnection of the refuelling hose
assembly to the refuelling receptacle.
1.3.18 Refuelling receptacle
Device connected to a vehicle or storage system that receives the refuelling nozzle and
permits safe transfer of CNG.
1.3.19 Refuelling hose assembly
A valve located in the refuelling hose assembly to stop the flow of gas and to depressurize
the section between the refuelling nozzle and the valve.
1.3.21 Screen wall
(b)
(c)
Persons, bodies or other entities appointed by the government under applicable legislation
in the respective state or territory to have jurisdiction over the implementation of safety and
other standards and regulations applicable to any refuelling station.
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AS 50922009
NOTE: Refer to Appendix A for a list of regulators, functions and contact details in each
jurisdiction.
(b)
supply pressure;
(c)
(d)
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AS 50922009
10
SECT ION
COMPONENTS
2.1 GENERAL
Enquiries shall be made of the natural gas supplier to determine whether there are any
components in the gas to be compressed that may adversely affect refuelling station
components or negatively impact on fuelling operations (refer Clause 1.6.1(c)).
All components shall be compatible with the natural gas to be compressed and shall be
designed or selected for the full range of pressures, temperature and loadings to which they
are subjected.
Where the natural gas supplied has a water content that, in conjunction with prevailing
ambient temperatures, gives rise to hydrate build-up to the extent that refuelling operations
are affected, then consideration should be given to the use of a gas drying system.
2.2 GAS-FIRED APPLIANCES
Gas-fired appliances used in the CNG refuelling station, e.g. gas engines for driving CNG
compressors, shall meet the requirements of AS 3814.
NOTE: State gas supply regulation may require that such gas-fired appliances be certified.
2.3 COMPRESSORS
2.3.1 General
Compressors shall be provided with clear and permanent markings that are readily
accessible and easy to read when the compressor is in the installed position.
Such markings shall include the following:
(a)
(b)
Model designation.
(c)
(d)
(e)
(f)
Operating speed.
(g)
2.3.2 Separators
Separators shall be fitted after compression stage coolers to remove, as far as is possible,
any oil, water or condensate droplets present in the gas.
2.3.3 Separator drainage
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Provision shall be made for the removal and collection of any liquids accumulating in the
separators. Any gas escaping with the drained liquid shall be separated and piped to the
compressor inlet.
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AS 50922009
The separator drainage system may be either manual or automatic. It shall be operated at
frequencies that ensure the re-entrainment of intercepted liquids is avoided.
2.3.4 Compressor unloading/blow down systems
Where an unloading/blow down system is incorporated the blown down gas shall be
returned to the compressor inlet and be designed to ensure that the rated pressure of the
inlet system is not exceeded.
2.3.5 Relief valves
Each stage shall be fitted with a spring-loaded relief valve sized for the compressor
capacity. The set pressure shall exceed the operational discharge pressure of the associated
stages to the extent necessary to avoid discharge in normal service (typically 15% for inter
stage and 10% for final stage relief valves) but shall not exceed the respective design rated
pressures.
Discharge piping of such relief valves shall be in accordance with Clause 3.8.2.
2.3.6 Instruments
Gas pressure(s)A pressure gauge that complies with Clause 2.7 shall be fitted after
each stage of gas compression.
(b)
(c)
(d)
(e)
(f)
Gas inlet train components used shall be in accordance with AS 5601 and any additional
requirements of the Technical Regulator (see Clause 1.3.22).
2.4.2 Compressor skid piping and hoses
Piping and hoses from the flexible hose at the compressor inlet connection, between
compression stages, coolers and separators and up to the non-return valve at the end of the
compressor outlet flexible piping, shall be in accordance with the compressor
manufacturers standard practice. The piping used shall have a rated pressure in excess of
the maximum pressures that can occur in the locations where the piping is used.
2.4.3 Discharge piping/tubing
All flexible hose assemblies used for gas transmission at pressures above 2.4 MPa shall
meet the requirements of AG 807.
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Flexible hose assemblies used for gas transmission at pressures below 2.4 MPa shall be
suitable for natural gas service and have rated pressures in excess of the maximum
pressures that can occur in the locations where they are used.
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AS 50922009
12
Flexible hose assemblies used for pressure sensing shall be suitable for natural gas service
and have rated pressures in excess of the maximum pressures that can occur in the locations
where they are used.
2.5 VALVES, PIPING AND TUBING COMPONENTS
2.5.1 General
All valves, pipes and components such as strainers, compression fittings and no break
couplings, separator bodies and similar fittings shall have a rated pressure in excess of the
maximum pressures that can occur in the locations where used. In addition, materials,
especially elastomers, shall be suitable for use with compressed natural gas.
The manufacturer shall stamp, or otherwise permanently mark, valves and components to
indicate the manufacturer's name or trademark and part number.
Isolating valves shall operate with a quarter turn from open to closed.
2.5.2 Gas inlet train
Valves and components up to and including the appliance valve(s) shall be in accordance
with AS 5601.
2.5.3 Valves and components for the compressor skid
From the compressor inlet to the non-return valve at the end of the compressor outlet
flexible piping, valves and components shall comply with the compressor manufacturers
standard practice.
2.5.4 Pressure valves
be clearly marked by their manufacturer or agent with the pressure at which they are
set to start to discharge;
(b)
have a rated discharge capacity greater than the input capacity from the system; and
(c)
not be fitted with lifting devices to prevent tampering by unauthorized persons; and
(d)
incorporate a means for adjusting the pressure set point that can be sealed.
shall comply with AS 1349 or equivalent and shall have a dial graduated to read
between 1.2 to 2 times the operating pressure; and
(b)
shall comply with AS 1349 or equivalent where used on storage vessels and shall
have a dial graduated to read between 1.2 to 2 times the maximum developed
pressure.
NOTE: For gauges at operating pressures of 2500 kPa or above, special provisions apply in
AS 1349.
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All electrical wiring and equipment shall be suitable for the specific hazardous area in
which it is located, in accordance with AS/NZS 3000.
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AS 50922009
Hose assemblies shall have rated pressures in excess of the maximum that can occur in the
refuelling process for which they are to be used. These hose assemblies shall consist of
(a)
a refuelling hose complying with Clause 2.4.4 with appropriate end connections for
attachment to the other hose assembly components. Hose assemblies shall be
hydrostatically tested, after assembly and prior to use, to at least twice the maximum
operating pressure for a minimum of 1 min. The hose assembly shall not leak, burst or
suffer damage from pressurization when hydrostatically tested;
(b)
(c)
(d)
(e)
a vent hose to convey the gas released from the operation of depressurizing the
refuelling connector to a safe place.
NOTE: Items (c) and (e) may not be required if the dispenser automatically depressurizes the
refuelling nozzle and hose at the end of the fill.
Refuelling connectors shall have rated pressures in excess of the maximum that can occur in
the refuelling process for which they are to be used. They shall consist of refuelling nozzles
and refuelling receptacles specifically designed for compressed natural gas service.
The refuelling connector shall enable gas to be transferred to the vehicle gas containers of
the vehicle being filled. When separated, the refuelling nozzle and refuelling receptacle
shall be self-sealing.
The refuelling nozzle shall be fitted to the refuelling hose assembly and the corresponding
refuelling receptacle shall be fitted to the vehicle to be filled.
For depot-based refuelling stations located on private property not available for use by the
public, the type and size of refuelling connector shall be as chosen by the station owner or
operator.
For public refuelling stations, the refuelling connector shall meet the requirements of
ISO 14469 (all parts).
2.11 REFUELLING HOSE ASSEMBLY BREAKAWAY COUPLINGS
2.11.1 Refuelling hose breakaway coupling
The refuelling hose assembly shall incorporate a breakaway hose coupling designed to
disconnect in the event of undue force being applied to the hose, such as a vehicle moving
off with the hose connected.
The coupling shall be designed in accordance with the following requirements:
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(a)
less than 600 N for hoses of nominal bore below 12.5 mm; or
(ii)
(b)
The coupling shall retain the gas within both sections of the hose after separation.
(c)
The coupling shall be located so as to ensure that the breakaway force is applied
axially.
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AS 50922009
14
The coupling should be capable of being reassembled after separation, preferably without
the use of special tools or the replacement of parts.
2.11.2 Vent hose breakaway coupling
The refuelling hose vent line, if fitted, shall also incorporate a breakaway hose coupling.
This coupling shall be designed so that the axial force required to separate it shall be less
than 100 N.
If the vent line is connected to the compressor system, a non-return valve shall be fitted to
prevent a backflow toward the refuelling connector.
2.11.3 Refuelling hose assembly attachment
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Lic
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The point of attachment of the refuelling hose assembly shall be capable of withstanding
twice the combined force necessary to separate the refuelling and vent hoses without it
causing damage or deformation.
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15
SECT ION
AS 50922009
I NSTA L L A T I ONS
Before commencing construction, all necessary permissions, licences and approvals shall be
obtained from local planning authorities, the Technical Regulators and other Authorities.
Licences to commission and operate shall be obtained, pressure vessels shall be registered
and, depending on the quantities of CNG stored, licences for the storage of dangerous goods
obtained.
It is the responsibility of the owner of the CNG refuelling station to contact the Authorities
and Technical Regulators to establish the timing and extent of the drawings and
documentation to be submitted for approval for construction, commissioning and operation
of the station.
NOTE: Appendix D contains a checklist that provides guidance on the aspects of the CNG
refuelling station that should be checked prior to putting the station into service and during
annual safety inspections.
When locating refuelling station equipment within any site, the separation distances to
public places, the overall site boundary and protected places, etc. shall satisfy local
Authority planning requirements relating to potentially hazardous developments,
occupational health and safety (OHS) regulations relating to dangerous goods and relevant
Australian Standards.
The impact of hazards arising from the presence of a CNG refuelling station and the
reciprocal hazards to such a refuelling station from any adjacent potentially hazardous plant
or equipment shall be taken into account. Where appropriate, e.g. when required by local
authorities or OHS regulations, separation distances shall be established using quantitative
risk analysis.
In all cases, the location of the refuelling station plant elements shall ensure that the
associated hazardous areas determined in accordance with AS/NZS 60079.10.1 are located
entirely within the overall site boundary.
All electrical equipment shall comply with and be installed in accordance with
AS/NZS 3000. Any pre-existing electrical equipment shall be either upgraded to comply
with these requirements or be relocated.
For the purposes of this Standard, where a motor vehicle enters a hazardous zone associated
with any part of the refuelling station, such a vehicle shall not be regarded as being an
ignition source.
Refuelling stations shall be protected against unauthorized entry by either
(a)
(b)
a chain link security fence complying with AS 1725 for heavy duty service, having as
a minimum, a height of 1800 mm and two lockable gates.
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NOTE: This requirement may be satisfied by the overall site boundary fence provided it
affords the same level of protection.
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AS 50922009
16
Dispensers shall be lockable or have other provisions for inhibiting their use when the site
is not manned. All equipment shall be protected from damage from vehicle movements
within the site by its location or by suitable walls, bollards, protective railing or other
appropriate measures.
3.2.1.2 Compressed gas storage systems
Compressed gas storages shall be located outdoors and separated from public places, the
site boundary and protected places in accordance with Table 3.1. Screen walls may be used
to reduce minimum separation distances as recommended in AS 4332.
TABLE 3.1
Minimum separation
distances (m)
150
See Note 3
>150
600
>600
2 500
>2 500
10 000
>10 000
To be determined by risk
analysis
150
150
600
>600
2 500
>2 500
10 000
>10 000
To be determined by risk
analysis
NOTES:
1
All gas volumes expressed in the above table are at 15C, 101.325 kPa absolute pressure.
The minimum separation distances for aggregate capacities up to 600 m 3 correspond to those for container
volumes (water capacities) up to 2000 L, as specified in AS 4332, with natural gas at a storage pressure of
25 MPa. For aggregate capacities up to 2000 L and storage pressures below 25 MPa, minimum separation
distances determined by AS 4332 as a function of container volume shall apply.
For compression equipment and dispensers, vapour barriers may be used to reduce
minimum separation distances. Any vapour barriers that are used shall be of a sufficient
length to maintain the required minimum separation distances. The height of the vapour
barriers shall be a minimum of 1 m above the height of the affected refuelling station
element.
Dispensers/fill posts shall have separation distances to public places, the site boundary and
protected places, and other elements of the refuelling station as specified in Table 3.2.
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17
AS 50922009
TABLE 3.2
0 (see Note 1)
Buildings
Openings in buildings
0 (Note 1)
0 (Note 1)
3 (see Note 2)
N/A
N/A
NOTES:
1
Where the hazardous area is defined as starting from the end of the refuelling hose.
This separation distance may be reduced to 0 where the vent gas arising from the depressurization of the refuelling
connector necessary to release the refuelling nozzle from the refuelling receptacle is contained or safely vented to
atmosphere outside of any hazardous area.
Additional requirements may apply to a public refuelling station. These shall be agreed to
by the involved parties on a case by case basis.
3.2.3 Mobile storage units
A parking bay shall be provided at both the compression station where the mobile storage
unit is refilled and at the refuelling station where gas is transferred for use.
Fencing, signage, illumination and fire protection shall be in accordance with applicable
Standards. The parking bay shall have a firm, compacted, well-drained foundation.
NOTE: A typical arrangement of a parking bay for mobile storage is shown in Appendix B.
3.2.4 Roofing
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There shall be at least one fire extinguisher of dry powder type having a rating of 6A:80B:E
in accordance with AS/NZS 1850, and an available capacity of at least 9 kg. An
extinguisher shall be available within 4 m of the gas compression equipment and gas
storage and dispenser/fill post.
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AS 50922009
18
NOTES:
1
Attention is drawn to dangerous goods and OHS regulations relating to the requirements for
fire protection for gas storages.
AS 2441 relates to the installation of fire hose reels and AS 2444 to fire extinguisher
selection and location.
3.2.6 Illumination
Stations at which refuelling will occur at night shall be equipped with fixed lighting capable
of providing illumination at a level of not less than 50 lux within the dispensing area.
3.2.7 Signs and notices
The following signs and notices shall be installed at CNG refuelling stations as a minimum:
(a)
(b)
This machine may start automatically at any time: Where compressors or other
equipment are subject to automatic starting.
(c)
Stop engine no smoking: Adjacent to areas where fuel transfer or dispensing takes
place.
(d)
(e)
(f)
(g)
All components used in the construction of a refuelling station shall meet the requirements
of Section 2 of this Standard.
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For the purposes of this Standard, the equipment comprising CNG refuelling stations
consists of the following elements:
(a)
The inlet gas train connecting from the gas supply to the compression equipment in
accordance with Clause 3.4.
(b)
(c)
A compressed gas storage system in accordance with Clause 3.6, usually for fast
filling stations.
(d)
Dispensers/fill posts for fast or time fill in accordance with Clause 3.7.
(e)
(f)
(g)
(h)
Other equipment such as fencing, equipment protection against damage from vehicle
collisions, fire protection, signs and notices, and lighting, in accordance with
Clause 3.2.
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19
AS 50922009
The inlet gas supply equipment shall meet the requirements of AS 5601 and any additional
requirements of the Technical Regulators.
The inlet gas supply equipment shall have rated pressures in excess of the inlet gas
equipment pressure relief valve setting.
The inlet gas supply equipment shall include the following:
(a)
(b)
(c)
A pressure relief valve fitted downstream of the non-return valve sized in accordance
with Clause 3.9.1.
(d)
A flexible connection between the inlet and the compressor piping in accordance with
Clause 3.5.
(e)
(f)
(g)
Additional isolating valves at each compressor where more than one compressor is
installed.
(b)
(c)
Gas compression equipment may be located in sound attenuating and/or weather protecting
enclosures or on open skids.
Flexible connections shall be provided at the inlet in accordance with Clause 3.4 and at the
outlet from the compression equipment to limit the transmission of vibrations from the
compression equipment to the fixed gas piping/tubing.
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A non-return and isolating valve shall be fitted immediately downstream of the compressor
outlet flexible connection.
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AS 50922009
20
One or more banks of compressed gas in gas containers either as a single unit or as
multiple units manifolded together with safety devices in accordance with Clause 2.6.
(b)
Interconnecting pipework and valves in accordance with Clauses 2.4 and 2.5.
(c)
(d)
A master shut off valve for each bank in accordance with Clause 3.8.3.
(e)
Cylinder storage units that have cylinders stored in a vertical position shall be limited to a
width of 1.1 m and a height of 1.6 m above floor level unless adequate access arrangements
are provided not more than 1.6 m below the valves.
Cylinder storage units that have cylinders stored in a horizontal position shall be limited to
a height of 2 m. To ensure ready access, all cylinder fittings shall be arranged on one end of
each unit.
Storage systems comprising horizontally disposed gas containers exposed to direct sunlight
shall be protected by a roof or canopy in accordance with Clause 3.2.4.
3.6.2 Mobile storage systems
Provisions shall be made for the reception and protection of mobile storage systems, in
accordance with Clause 3.2.3, where they are used to transfer gas to a refuelling station.
3.7 DISPENSERS/FILL POSTS
3.7.1 Minimum requirements
Refuelling hose assembly in accordance with Clause 2.9 fitted with a refuelling
nozzle in accordance with 2.11 and breakaway coupling in accordance with
Clause 2.12.
(b)
(c)
(d)
(e)
A safety relief valve downstream of the hose isolating valve set to limit the pressure
in the fill hose from exceeding 110% of the maximum vehicle cylinder fill pressure.
(f)
A hose assembly refuelling connector rest position and means of hose assembly
support designed to facilitate ease of use, avoid hose kinking and ensure that the hose
assembly is not in contact with the ground when at rest and in normal use.
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Interconnecting pipework and fittings including vent piping for safe disposal of vent gas
from the safety relief valves and vent hoses where the latter are incorporated in the
refuelling hose assembly, shall be in accordance with Section 2.
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21
AS 50922009
Where the vent hose is connected back to the inlet of the compression equipment, it shall be
fitted with a non-return valve to prevent flow towards the refuelling connector.
A means shall be provided for locking the refuelling hose assembly in its rest position or
otherwise inhibiting unauthorized dispenser operation when the installation site is not
attended.
NOTE: Additional requirements for public refuelling stations may be determined according to the
Technical Regulators and the site owner and/or operator.
A means of measuring and indicating the amounts of gas dispensed locally and/or
remotely.
(b)
A hose vent valve for connection to a vent gas recovery system where the refuelling
hose assembly is not fitted with a vent hose and is to be handled depressurized.
(c)
(d)
Sequencing valves for optimizing gas storage utilization and vehicle filling in
accordance with Clause 3.9.4.
Any slow fill stations shall comprise at least the minimum components listed in
Clause 3.7.1. Slow fill stations may be presented on a post or contained in a pit with an
access lid to connect the fill hose to the vehicle to be filled.
3.8 HIGH PRESSURE DISCHARGE SYSTEM
3.8.1 General
The high pressure discharge system comprises piping/tubing, valves and fittings between
the compressor outlet(s), the gas storage system and the dispensers/fill posts.
The system rated pressure shall take into account the compressor maximum discharge
pressure (see Clause 2.3.5). All components of the high pressure discharge system shall be
rated for this pressure.
3.8.2 High pressure piping/tubing
3.8.2.1 Design and layout
All piping/tubing shall be run as directly as practicable with adequate provision for
expansion, contraction, jarring, vibration and settling. The number of joints shall be kept to
a minimum.
Where overhead piping crosses the vehicle access way it shall be at least 4.6 m above
ground or as determined by the Technical Regulators.
All piping/tubing shall be adequately supported at intervals no less than required by
AS 4041 and protected against mechanical and corrosive damage.
Piping buried underground shall be coated and cathodically protected to AS 2832.1.
The minimum depth for buried piping shall be 750 mm subject to increased depth
dependent on any specific local soil conditions, vehicle weight and movements. Care must
be taken to select back fill materials that will not damage the pipe coating.
The as installed location of all buried underground pipeline shall be accurately recorded.
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Test connections shall be provided where pressure readings are desired for diagnostic
purposes.
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AS 50922009
22
Pressure relief discharge piping shall comply with the following requirements when
installed:
(a)
The rated pressure for discharge piping shall be in accordance with AS 4041.
(b)
The discharge piping size shall be sufficient to ensure the required relief flow rate is
achieved.
(c)
The direction of discharge shall not permit escaping gas to impinge on any piping or
structure.
(d)
Except for measures necessary to prevent ingress of rainwater or blockage into the
relief device, venting shall be direct to atmosphere.
(e)
The discharge terminal shall be in accordance with the requirements for vent
terminals outlined in AS 5601.
(f)
When designing the discharge piping, due consideration shall be given to the forces
generated by the discharging gas.
(g)
The outlet shall not be vulnerable to physical damage and shall be fitted with suitable
covers to prevent the ingress of water and dirt.
3.8.2.2 Fabrication
Discharge piping and tubing shall be fabricated to comply with the requirements of
AS 4041 (see Clause 2.4.3).
3.8.3 High pressure valves, fittings and safety devices
3.8.3.1 Isolating valves
(b)
(c)
Master shut off valve(s) for each storage bank located immediately outside the
storage enclosure. In the case of multiple valves these shall be located adjacent to
each other.
(d)
At the dispenser/fill post piping immediately before the fill hose, in accordance with
Clause 3.7, in a position readily accessible to the person refuelling the vehicle.
(e)
At the end of the refuelling hose assembly in accordance with Clause 2.9.
(b)
In the vent line where the refuelling hose vent is connected to the compressor suction
side in accordance with Clause 3.9.1.
3.8.3.3 Components
Fittings for the high pressure discharge system shall comply with Section 2 and may be
used as required for the following applications:
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(a)
Filtration of the gas stream to the extent required by the end user.
Standards Australia
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23
(b)
(c)
Joining piping and tubing i.e. compression and face seal type joints.
(d)
AS 50922009
Safety devices shall be provided for compressors in accordance with Clause 2.3.5. They
shall be provided for pressure vessels and gas containers in accordance with Clause 2.6 and
for the refuelling hose(s) in accordance with Clause 3.7.1.
Vent piping, where appropriate, shall be in accordance with Clause 3.8.2.
Where there is a refuelling hose assembly vent line connected back to the inlet gas supply,
the inlet system relief valve shall be sized to accommodate a vehicle refuelling connector
malfunction (i.e. failure to close on venting) to limit the pressure rise in the inlet gas supply
equipment to not more than 110% of its design maximum working pressure when its source
pressure is the maximum vehicle refuelling pressure.
3.9.2 Compressor protection switches/devices
(b)
A pressure switch for high outlet pressure set above the normal control system
storage full compressor stop pressure and below the compressor discharge relief valve
setting.
(c)
A pressure switch for low oil pressure and/or level set to the manufacturers
specifications.
(d)
An emergency stop switch that, depending on location, may serve more than one
compressor.
(e)
A pressure switch for high inlet pressure where the gas supply pressure can exceed
the compressor maximum inlet pressure.
(f)
A temperature switch for high gas outlet temperature set to the manufacturers
specifications.
Each compressor with hydraulically operated pistons shall be fitted with the following
protection switches/devices integrated into the control system in accordance with
Clause 3.10.2:
(i)
(ii)
Dispensers and/or fill posts for both public and non-public access stations shall incorporate
pressure controls to ensure that the maximum refuelling pressures shall not exceed the
limits specified by the CNG fuel cylinder standard of the cylinders fitted to the vehicles to
be refuelled.
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For fast fill systems without a temperature compensated pressure control system, the
maximum fill pressure shall be 20 MPa.
www.standards.org.au
Standards Australia
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AS 50922009
24
For fast fill systems with a temperature compensated pressure control system the refuelling
control system shall limit the vehicle refuelling pressure to that specified by ISO 11439,
CSA B51 Part 2 or ANSI/IAS NGV 2, i.e. 20 MPa at 15C, but in no case shall the fill
pressure exceed 26 MPa.
For non-public and special purpose refuelling stations that service vehicles with CNG fuel
cylinders to standards other than ISO 11439, CSA B51 Part 2 or ANSI/IAS NGV 2 where
the rated fill pressure for these vehicle fuel cylinders is below that specified by these
Standards, the vehicle refuelling receptacles shall be of an approved type that does not
allow connection to ISO 14469 refuelling nozzles. This will avoid the possibility of
exceeding the maximum fill pressure for these cylinders.
3.9.4 Controls for gas storage and vehicle filling
Controls for the optimizing of storage utilization and vehicle filling are not mandatory but
may be included as agreed between the owner and station constructor and may be all
mechanical or a combination of valves and control devices.
The location of such controls may be at the storage and/or the dispenser locations or as
decided by the station constructor.
3.10 POWER AND CONTROL ELECTRICAL SYSTEMS
3.10.1 Power electrics
Electric motors, starters and distribution boards together with associated cabling shall
comply with AS/NZS 3000. They shall also comply with the requirements of the gas
supplier, local electrical supplier and Technical Regulator(s).
3.10.2 Control systems
Control systems devices shall comply with Standards for the protection of electrical
equipment, AS/NZS 3000 and related Australian Standards for equipment located in
hazardous areas.
Control systems shall be designed to meet the refuelling station requirements as agreed with
the purchaser and operator. They should provide protection to all electrical equipment with
the incorporation of protection switches in accordance with Clause 3.9.
Control systems may use hard wired relays and/or programmable logic controllers (PLCs)
and shall meet the following minimum requirements:
(a)
The operation of the protection switches (see Clause 3.9.2) shall stop and lock out the
affected compressor.
(b)
The inclusion of an indicator shall show when a shutdown is due to a fault and
additional indicators shall show which fault has initiated the shutdown.
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NOTE: Emergency stop switch(es) may be required by the purchaser at other locations.
Standards Australia
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25
SECT ION
TEST IN G
AS 50922009
AND
COMM I SS ION I N G
4.1 GENERAL
Attention is drawn to the testing and commissioning required by relevant Authorities and
particularly those of the involved Technical Regulators for the gas and electricity
installations.
NOTE: Appendix D contains a checklist that provides guidance on the aspects of the CNG
refuelling station that should be checked prior to putting the station into service and during
annual safety inspections.
The station contractor shall submit documentation to the extent and in the format required
to enable Technical Regulators to assess the compliance of the station with the appropriate
acts, regulations and Standards and shall obtain from these Technical Regulators any
licences and/or permissions required before testing and commissioning can commence.
Copies of compliance documentation shall be kept on site during testing, commissioning
and operation.
4.3 WORKS TEST RESULTS
Copies of works test and certificates shall be kept on site during testing and commissioning
and operation. These shall include
(a)
(b)
(c)
(d)
safety relief valve certificates and other equipment test results relevant to
commissioning.
The station contractor shall prepare and document the testing and commissioning
procedures to be used and agree to the program for inspections and/or approvals with the
Technical Regulators.
The testing and commissioning procedures shall comply with the requirements of the
equipment manufacturers.
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www.standards.org.au
Standards Australia
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AS 50922009
26
SECT ION 5
OPERAT I O N
MA I NT E N A N CE
AND
5.1 GENERAL
(b)
(c)
when all fitted control and safety devices are functioning correctly.
Gas shall not be vented from the refuelling station to the atmosphere during normal
operation. However, this shall not preclude the venting of gas for disconnecting the
refuelling connector and any gas so released shall be led to a safe point of discharge.
NOTE: Appendix D contains a checklist that provides guidance on the aspects of the CNG
refuelling station that should be checked prior to putting the station into service and during
annual safety inspections.
(b)
Maintenance procedures shall cover regular testing, inspection, and monitoring of the
equipment.
(c)
Emergency procedures shall cover any action to be taken in the event of fire, leakage,
accident, equipment failure or other abnormalities or emergencies.
(d)
Training procedures shall cover all aspects of operating, maintenance, and emergency
functions.
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The operating procedures shall take into account the following, as appropriate to the
particular station:
(a)
(b)
(c)
(d)
(e)
Treatment of leakage.
(f)
Standards Australia
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(g)
(h)
Personnel safety.
(i)
(j)
(k)
(l)
Vehicle movement.
AS 50922009
Maintenance procedures shall take into account the following, as appropriate to the
particular station:
(a)
(b)
(c)
Gas purging.
(d)
(e)
Control of contractors.
(f)
Work authorization.
(g)
Firefighting equipment.
(h)
Pipelines.
(i)
(j)
(k)
Electric equipment.
(l)
Ventilation systems.
(m)
(n)
Illumination.
(o)
The needs of any other individual items or plant components, taking into account any
manufacturers maintenance instructions.
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(b)
Chain of command.
(c)
Duty list.
(d)
(e)
(f)
(g)
Contractors.
(h)
Site plan.
www.standards.org.au
Standards Australia
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AS 50922009
28
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Area housekeeping.
(j)
(k)
The conditions and obligations associated with work permits, confined-space entry
permits.
NOTE: Particular care should be taken to ensure personnel for whom English is a second
language comprehend the training.
5.2.7.2 Visitors
have their details recorded together with their entry and exit times;
(b)
wear a visitor badge and all personal protection equipment designated for the areas
they are visiting;
(c)
be instructed in the evacuation procedures that apply in the event of a fire or other
incident; and
(d)
be accompanied at all times to ensure compliance with all safety instructions and
notices.
All operational and maintenance work shall be planned and supervised by responsible staff
who shall ensure that all necessary precautions are observed.
5.4 RECORDS
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Lic
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(b)
routine inspection and testing of equipment in accordance with Clause 5.6; and
(c)
Standards Australia
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29
AS 50922009
No station or part thereof shall be put into service until operating and emergency
procedures and associated equipment are available, appropriate to the area being put into
service, and adequate personnel are available to cope with any possible fault condition.
5.5.2 Outlets not in use
Any outlet that is not in use shall be capped or otherwise blanked off to prevent inadvertent
release of gas, irrespective of whether a valve is fitted.
5.5.3 Ignition sources
No ignition source shall be introduced into a hazardous area except for welding, cutting and
similar operations, which shall be conducted only at specifically authorized times and
places, in accordance with the provisions of AS 1674.1.
5.5.4 Illumination
No work shall be carried out without adequate illumination. Electrical hand lamps shall not
be taken into a hazardous area unless approved for the purpose.
5.6 SPECIFIC MAINTENANCE, INSPECTION AND TESTING
5.6.1 General
Inspection and safety checks of the station shall be carried out to keep the whole station in
safe operating condition at all times.
5.6.2 Scheduled inspections and tests
5.6.2.1 Inspections based on usage
A leakage test of pipe work and joints shall be carried out and all leaks rectified.
(b)
All components shall be visually inspected and any that are substandard shall be
replaced. Particular attention shall be given to pressure regulators, safety devices and
flexible piping.
(c)
Refuelling hoses shall be tested annually using the procedure in Clause 2.9, Item (a).
(d)
The breakaway coupling shall be tested annually by applying an axial force to ensure
the coupling safely operates in accordance with the requirements of Clause 2.11.1.
(ii)
ral
Lic
en
NOTE: Refer to AS/NZS 60079.17 for inspection of electrical equipment in hazardous areas, and
AS/NZS 3000 for inspection of electrical equipment in non-hazardous areas.
www.standards.org.au
Standards Australia
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AS 50922009
30
(b)
Safety relief devices other than burst discs shall be inspected and tested at intervals not
exceeding five years, as specified by the Technical Regulators.
Safety relief devices in service shall be maintained in reliable operating condition by
observing the following procedures:
(a)
Exercising care in handling and storage to avoid damage to a cylinder and connected
components.
(b)
(c)
Fusible plugs shall be externally examined for evidence of extrusion during scheduled
inspections in accordance with Clauses 5.6.2.1 and 5.6.2.2. Action shall be taken to replace
fusible plugs found with evidence of extrusion.
All replacements of safety relief devices or parts thereof shall be executed by suitably
qualified personnel using parts or assemblies that meet the requirements of this Standard.
If at any time it is necessary to break a seal on a safety relief device, the device shall be
removed from service, reset and sealed to the satisfaction of the Technical Regulators.
5.6.2.5 Fire protection equipment
No work shall be carried out within any hazardous area without authorization by a person
designated by the owner/operator of the station via one of the following:
(a)
(b)
(c)
A work permit, to deal with potentially hazardous activities requiring close attention.
ral
Lic
en
A work permit shall be issued only by a person designated by the owner/operator of the
station. The permit shall include statements of the following:
(a)
(b)
(c)
(d)
(e)
Standards Australia
www.standards.org.au
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31
AS 50922009
(f)
Any regular checking necessary to ensure that the safety requirements and conditions
remain in force.
(g)
Any procedures and precautions necessary to return the plant to normal service.
(h)
Work on or near any gas-containing components shall be undertaken only after all
necessary steps have been taken to ensure safety. Particular attention shall be paid to the
following:
(a)
(b)
Protective devices shall not be removed unless substitute protection has been
provided.
(c)
(d)
Any person who issues a work permit shall be responsible for ensuring that the site area and
plant are properly prepared to prevent the danger of fire or explosion, subject to the work
permit. Precautionary measures shall include the following, as appropriate:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
When work covered by a work permit has been completed, the person who issued the work
permit shall, before allowing the plant to be returned to service, ensure that
(a)
(b)
any temporary arrangements have been discontinued, e.g. bypass lines or blank
flanges have been removed, fuses replaced;
(c)
(d)
Any work within a hazardous area involving cutting or welding by gas or electric arc or any
non-welding work of equivalent risk, e.g. grinding, drilling or the use of percussion tools,
shall not be undertaken unless a work permit has first been obtained.
ral
Lic
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www.standards.org.au
Standards Australia
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AS 50922009
32
Any work for which a work permit is not required shall be sufficiently supervised by a
competent person(s) to ensure the safe conduct of the work.
5.6.10 Equipment alterations
Any work that is likely to create an ignition source within a hazardous area shall be
undertaken in accordance with AS 1674.1 and the area shall be monitored to ensure that it
remains gas-free.
5.6.12 Site upkeep
The area around any storage and compressor station shall be maintained in a safe condition.
ral
Lic
en
In particular
(a)
(b)
(c)
(d)
(e)
(f)
Standards Australia
www.standards.org.au
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33
AS 50922009
APPENDIX A
The following information is for guidance only and may be subject to change:
Federal,
State or
Territory
Function
Fax
National
Measurement
Institute
Bradfield Road
Lindfield NSW 2070
Australian
Capital
Territory
Dangerous goods
transport and
storage, CNG
storage cylinders
ACT WorkCover
Gas technical
regulation
PO Box 1908
Canberra ACT 2601
CNG dispenser
metering
Northern
Territory
ral
Phone
Dispenser meter
approval
Dangerous goods
transport and all
other matters
en
Contact Address
Federal
Lic
Authority
WorkCover NSW
Gosford general
enquiries:
(02) 4321 5000
Gas technical
regulation
Department of
Water and Energy
CNG dispenser
metering
Office of Fair
Trading
1 Fitzwilliam St
Parramatta NSW 2150
13 32 20
Dangerous goods
transport, storage
and gas technical
regulator
Office of Work
Health and
Electrical Safety
CNG dispenser
metering
Trade Measurement,
Department of
Justice
www.standards.org.au
or
131 555
Environment Line
(within NSW)
Standards Australia
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AS 50922009
Federal,
State or
Territory
34
Function
Dangerous goods
storage
Authority
Contact Address
Phone
Fax
Queensland
Transport
Principal Engineer
(Dangerous Goods)
PO Box 673
Fortitude Valley QLD 4006
Workplace Health
and Safety
Queensland
PO BOX 69
Brisbane QLD 4001
(07)3225 1540
Department of
Industrial Relations
ral
Lic
en
South
Australia
Gas technical
regulation
Department of
Natural Resources,
Mines and Energy
CNG dispenser
metering
Trades and
Measurements
Section - Office of
Fair Trading,
Department of
Tourism and Fair
Trading
Dangerous goods
transport and
storage
Safework SA
Manager
Department of the
Dangerous Substances
Premier and Cabinet GPO Box 465
Adelaide SA 5001
Gas technical
regulation
CNG dispenser
metering
Trade Measurements
Branch, Office of
Consumer and
Business Affairs
Principal Gas
Advisor/Engineer
Level 8 ANZ Building (City
Central Tower 1)
11 Waymouth Street
Adelaide SA 5001
Tasmania
Victoria
Dangerous goods
transport and
storage
Victorian
Workcover
Authority
Gas technical
regulation
CNG dispenser
metering
Trade Measurement,
Office of Fair
Trading
Standards Australia
Manager
Dangerous Goods
GPO Box 4306
Melbourne VIC 3001
www.standards.org.au
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35
Federal,
State or
Territory
ral
Lic
en
Western
Australia
Function
Authority
Contact Address
AS 50922009
Phone
Fax
Dangerous goods
transport and
storage
Resources Safety
Division
Department of
Mines and
Petroleum
Director
Resources Safety Division
303 Sevenoaks Street
Cannington WA 6107
or
Locked Bag 14
Cloisters Square WA 6850
Gas technical
regulator
Energy Safety
Division
Department of
Commerce
CNG dispenser
metering
Trade Standards
Manager
Branch, Department Trading Standards Branch
of Commerce
321 Selby Street
Osborne Park WA 6017
or
Locked Bag 14
Cloisters Square WA 6850
www.standards.org.au
Standards Australia
APPENDIX B
(Informative)
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en
Lic
AS 50922009
Standards Australia
36
www.standards.org.au
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R
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Lic
02
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37
AS 50922009
APPENDIX C
C1 BEFORE REFUELLING
The CNG vehicle identification labels are approved and on the vehicle registration
plates.
(b)
(c)
The vehicle handbrake is firmly applied and the vehicle parked in gear or P (with
automatic transmission).
(d)
(e)
The vehicle gas cylinder(s) is/are not overdue for periodic re-certification.
NOTE: This is to be done by checking that the retest date displayed on the refuelling
information plate has not passed, either manually or automatically via a tag reader, the latter
interlocked to prevent refuelling if the cylinder certification is not current.
(f)
C2 REFUELLING PROCEDURE
(b)
(c)
Remove the refuelling hose from its rest position and connect the refuelling nozzle to
the vehicle refuelling receptacle.
(d)
Initiate the filling process according to the site specific instructions displayed and
ensure that refuelling connector is not leaking.
NOTE: Once the refuelling flow has commenced, the person refuelling the vehicle should keep a
distance from the refuelling connector and refuelling hose at least equal to the length of the
refuelling hose.
follow the site specific instructions displayed, remove refuelling nozzle from the
vehicle refuelling receptacle and return the refuelling hose to its rest position;
(ii)
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Standards Australia
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AS 50922009
38
APPENDIX D
D1 GENERAL
It is recommended that the owner/operator obtain from the station contractor a statement of
compliance with this Standard. The following list provides guidance on the aspects that
should be checked prior to putting equipment into service and during annual safety
inspections.
The involvement of the Technical Regulators may vary from that assumed in this list
depending on individual state and territory regulations and practices and the size and
complexity of the station.
D2 CHECKLIST FOR PUTTING STATION INTO SERVICE AND SAFETY
INSPECTION FOR REFUELLING STATIONS
Item
Clause reference/
details/comments
Tick
3.1
4.2
3.2
Is the site on which the refuelling facility is located fully fenced and
secured? If not, is the equipment secured in enclosures or behind
security fencing?
3.2
3.2
3.2.6
3.2.7
3.2.5
3.2.7
Has the Technical Regulator been made aware of the intended station
of a gas pressure raising device?
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4.3
Have all pressure vessels been assessed for Hazard Level as specified
in AS 4343 and certificates provided for those classified as D and
above?
4.3
Standards Australia
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Item
AS 50922009
Clause reference/
details/comments
Tick
3.1
Has the maximum quantity of stored gas been established and a license
obtained for the storage of dangerous goods if required according to
state and territory regulations?
4.2
Electrical supply
3.1, 4.4
3.1, 4.4
4.4
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5.2
Has the operational staff been trained with arrangements for refresher
training at intervals?
5.2.7
5.2.6
5.6
www.standards.org.au
Standards Australia
APPENDIX E
(Informative)
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Standards Australia
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Standards Australia
Standards Australia develops Australian Standards and other documents of public benefit and national interest.
These Standards are developed through an open process of consultation and consensus, in which all interested
parties are invited to participate. Through a Memorandum of Understanding with the Commonwealth Government,
Standards Australia is recognized as Australias peak non-government national standards body. Standards Australia
also supports excellence in design and innovation through the Australian Design Awards.
For further information visit www.standards.org.au
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Committees of experts from industry, governments, consumers and other relevant sectors prepare Australian
Standards. The requirements or recommendations contained in published Standards are a consensus of the views
of representative interests and also take account of comments received from other sources. They reflect the latest
scientific and industry experience. Australian Standards are kept under continuous review after publication and are
updated regularly to take account of changing technology.
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Standards Australia is responsible for ensuring the Australian viewpoint is considered in the formulation of
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vital in assisting local industry to compete in international markets. Standards Australia represents Australia at both
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Australian Standards, Handbooks and other documents developed by Standards Australia are printed and
distributed under license by SAI Global Limited.
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