AS 5092—2009

Australian Standard®

CNG refuelling stations

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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.

The following are represented on Committee AG-009:

• Association of Accredited Certification Bodies • Bus Industry Confederation • CNG Refuelling System Suppliers • Department for Transport, Energy and Infrastructure, SA • Department of Consumer and Employment Protection, WA • Department of the Premier and Cabinet, SA • Energy Networks Association • International Association for Natural Gas Vehicles • Motor Trades Association of Australia • State Public Transport Operations Interests

This Standard was issued in draft form for comment as DR 08098. 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.

Keeping Standards up-to-date 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 Standards may also be withdrawn.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 Standards Australia welcomes suggestions for improvements, and encourages readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at mail@standards.org.au, or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.

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AS 5092—2009

Australian Standard®

CNG refuelling stations

Originated as AG 504—1987. Previous edition AG 901—1996. Revised and redesignated as AS 5092—2009.

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

ISBN 0 7337 9260 X

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AS 5092—2009 2

PREFACE

This Standard was prepared by the Standards Australia Committee, AG-009, Natural Gas

Vehicle Refuelling Stations, to supersede AG 901—1996, 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 with—but

do not take precedence over—any Statutory Regulations that may apply. In its preparation

consideration has been given to—

(a) continuity of satisfactory operation of components and equipment;

(b) the prevention of injury to persons or property;

(c) the prevention of fire hazards and explosions;

(d) gas rules and regulations now in force; and

(e) relevant Australian Standards as identified in Clause 1.2.

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.

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 5092—2009

CONTENTS

Page

SECTION 1 SCOPE AND GENERAL

1.1 SCOPE ........................................................................................................................ 5

1.2 REFERENCED DOCUMENTS .................................................................................. 5

1.3 DEFINITIONS ............................................................................................................ 6

1.4 ADDITIONAL REQUIREMENTS FOR PUBLIC REFUELLING STATIONS.......... 9

1.5 APPROVALS.............................................................................................................. 9

1.6 SUPPLY ENQUIRIES................................................................................................. 9

SECTION 2 COMPONENTS

2.1 GENERAL ................................................................................................................ 10

2.2 GAS-FIRED APPLIANCES...................................................................................... 10

2.3 COMPRESSORS....................................................................................................... 10

2.4 PIPING (INCLUDING FLEXIBLE PIPING/HOSES AND TUBING)...................... 11

2.5 VALVES, PIPING AND TUBING COMPONENTS ................................................ 12

2.6 SAFETY DEVICES FOR PRESSURE PROTECTION............................................. 12

2.7 PRESSURE GAUGES............................................................................................... 12

2.8 ELECTRICAL EQUIPMENT AND WIRING........................................................... 12

2.9 REFUELLING HOSE ASSEMBLIES ...................................................................... 13

2.10 REFUELLING CONNECTORS................................................................................ 13

2.11 REFUELLING HOSE ASSEMBLY BREAKAWAY COUPLINGS ......................... 13

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

SECTION 4 TESTING AND COMMISSIONING

4.1 GENERAL ................................................................................................................ 25

4.2 STATION COMPLIANCE DOCUMENTATION..................................................... 25

4.3 WORKS TEST RESULTS ........................................................................................ 25

4.4 COMMISIONING DOCUMENTATION AND RECORDS...................................... 25

SECTION 5 OPERATION AND MAINTENANCE

5.1 GENERAL ................................................................................................................ 26

5.2 ESTABLISHMENT OF PROCEDURES .................................................................. 26

5.3 SUPERVISION ......................................................................................................... 28

5.4 RECORDS................................................................................................................. 28

5.5 SPECIFIC OPERATING PROCEDURES................................................................. 29

5.6 SPECIFIC MAINTENANCE, INSPECTION AND TESTING ................................. 29

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AS 5092—2009 4

Page

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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STANDARDS AUSTRALIA

Australian Standard

CNG refuelling stations

S E C T I O N 1 S C O P E A N D G E N E R A 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) a combination of fast fill and time fill.

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) Liquefied Natural Gas (LNG) refuelling stations; or

(ii) Vehicle Refuelling Appliances (VRA) installations, which are covered by AG 806.

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.

2 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.

1.2 REFERENCED DOCUMENTS

The documents below are referred to in this Standard.

AS

AG 807 Approval requirements for natural gas flexible hose and hose assemblies for

pressures above 2.6 MPa

1349 Bourdon tube pressure and vacuum gauges

1530 Methods for fire tests on building materials, components and structures

1530.4 Part 4: Fire-resistance test of elements of construction

1674 Safety in welding and allied processes

1674.1 Part 1: Fire precautions

1725 Chain-link fabric security fencing and gates

1851 Maintenance of fire protection systems and equipment

2030 Gas cylinders

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AS

2441 Installation of fire hose reels

2444 Portable fire extinguishers and fire blankets—Selection and location

2473 Valves for compressed gas cylinders

2473.1 Part 1: Specifications, type testing, and manufacturing tests and inspections

2832 Cathodic protection of metals

2832.1 Part 1: Pipes and cables

3814 Industrial and commercial gas-fired appliances

4041 Pressure piping

4332 The storage and handling of gases in cylinders

4343 Pressure equipment—Hazard levels

4564 Specification for general purpose natural gas

5601 Gas installations

AS/NZS

1850 Portable fire extinguishers—Classification, rating and performance testing

3000 Electrical installations (known as the Australian/New Zealand Wiring Rules)

3788 Pressure equipment—In-service inspection

60079 Explosive atmospheres

60079.10.1 Part 10.1: Classification of areas—Explosive 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 Gas cylinders—High pressure cylinders for the on-board storage of natural gas

as a fuel for automotive vehicles

14469 Road vehicles—Compressed natural gas (CNG) refuelling connector

ANSI

ANSI/IAS

NGV 2

Basic Requirements for Compressed Natural Gas Vehicle (NGV) Fuel

Containers

CSA

CSA B51 Part 2: Boiler, Pressure Vessel and Pressure Piping Code

1.3 DEFINITIONS

For the purposes of this Standard, the definitions below apply.

1.3.1 Approved, approval

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).

NOTE: See Appendix A for more information.

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1.3.3 Compressed natural gas (CNG)

A compressed gaseous fuel composed of natural gas of pipeline quality as defined in

AS 4564.

1.3.4 Compressed gas storage systems

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.

It is expressed in minutes in the above order (e.g. 60/60/30).

1.3.7 Hazardous area (on account of explosive gas atmospheres)

An area in which an explosive gas atmosphere is or may be expected to be present in such

quantities as to require special precautions for the construction, installation and use of

equipment.

1.3.8 Ignition source

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.

1.3.9 Master shut off valve

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

A valve which permits flow in one direction only.

1.3.12 Operating pressure

The internal pressure to that a pressure containing component is subjected under normal

operating conditions.

1.3.13 Pressure

Gauge pressure unless noted as absolute pressure.

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AS 5092—2009 8

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1.3.14 Protected place

Any of the following:

(a) 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) A ship lying at permanent berthing facilities.

(d) Any storage facility for dangerous goods that is outside the property boundary of the

station.

1.3.15 Public place

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

Joined assembly of refuelling nozzle and receptacle.

1.3.17 Refuelling nozzle

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

An assembly incorporating a flexible hose, a breakaway coupling, a refuelling hose valve

(where used) and a refuelling nozzle.

1.3.20 Refuelling hose valve

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

A structurally sound wall that—

(a) has a fire resistance level (FRL);

(b) is impervious to vapour; and

(c) is constructed of materials that are substantially resistant to attack by the substances

being screened.

1.3.22 Technical Regulator

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.

1.3.23 Vapour barrier

An impervious, non-combustible barrier constructed with the object of preventing the passage of

vapour from any one place to another.

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1.4 ADDITIONAL REQUIREMENTS FOR PUBLIC REFUELLING STATIONS

Additional requirements applying to public refuelling stations should be agreed on a case by

case basis between the involved parties (station constructor, technical regulator(s), site

owner and operator, and the relevant certifying/accrediting bodies).

1.5 APPROVALS

1.5.1 Technical Regulators’ requirements

A refuelling station shall meet the requirements of the Technical Regulators.

NOTE: Refer to Appendix A for a list of regulators, functions and contact details in each

jurisdiction.

1.6 SUPPLY ENQUIRIES

1.6.1 Gas supplier

At a preliminary stage, an application should be addressed to the gas supplier regarding—

(a) natural gas availability;

(b) supply pressure;

(c) gas specification; and

(d) gas connection, gas equipment and piping installation.

1.6.2 Electricity supplier

At a preliminary stage, an application should be addressed to the electricity supplier

regarding electricity supply and installation requirements.

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AS 5092—2009 10

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S E C T I O N 2 C O M P O N E N T S

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

These requirements apply to mechanically, electrically or hydraulically powered

compressors designed for the compression of natural gas.

Compressors intended for outdoor installation shall have all controls and electrical wiring

adequately protected from climatic conditions to ensure safe and reliable operation.

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) Manufacturer's trade name.

(b) Model designation.

(c) Serial number and year of manufacture.

(d) Rated capacity at a designated inlet pressure.

(e) Maximum discharge pressure.

(f) Operating speed.

(g) Maximum and minimum supply pressure.

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

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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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 compressors shall be fitted with indicators to monitor the following:

(a) Gas pressure(s)—A pressure gauge that complies with Clause 2.7 shall be fitted after

each stage of gas compression.

(b) Lubricating oil pressure(s) (if applicable)—Equipment utilizing pressure lubrication

system(s) shall be fitted with an oil pressure gauge (or gauges).

(c) Crankcase pressure (if applicable)—Compressors with a crankcase operating under

positive pressure should be fitted with a crankcase pressure gauge.

(d) Temperature(s)—Temperature measurement shall be provided on the outlet of the

compressor.

(e) Oil level(s)—Provision shall be made to indicate all oil level(s).

(f) Provision shall be made to indicate ‘hours run’.

2.4 PIPING (INCLUDING FLEXIBLE PIPING/HOSES AND TUBING)

2.4.1 Gas inlet train components

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

Discharge piping/tubing shall be in accordance with AS 4041 or equivalent Standard.

2.4.4 Hose assemblies (other than compressor skid hoses)

All flexible hose assemblies used for gas transmission at pressures above 2.4 MPa shall

meet the requirements of AG 807.

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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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 manufacturer’s

standard practice.

2.5.4 Pressure valves

Cylinder valves shall comply with AS 2473.1 or an equivalent Standard.

2.6 SAFETY DEVICES FOR PRESSURE PROTECTION

Spring controlled pressure relief valves shall—

(a) 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.

2.7 PRESSURE GAUGES

Pressure gauges—

(a) shall comply with TAS 1349 T or equivalent and shall have a dial graduated to read

between 1.2 to 2 times the operating pressure; and

(b) shall comply with TAS 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.

2.8 ELECTRICAL EQUIPMENT AND WIRING

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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2.9 REFUELLING HOSE ASSEMBLIES

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) a refuelling nozzle (see Clause 2.10) either as a separate refuelling nozzle or

combined with a refuelling valve;

(c) a refuelling valve, which shall incorporate a means of depressurizing the refuelling

connector to enable separation of the refuelling hose from the vehicle being filled;

(d) breakaway couplings in accordance with Clause 2.11; and

(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.

2.10 REFUELLING CONNECTORS

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:

(a) The axial force required to separate the coupling shall be—

(i) less than 600 N for hoses of nominal bore below 12.5 mm; or

(ii) less than 800 N for hoses of nominal bore of 12.5 mm or greater.

(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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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

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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S E C T I O N 3 I N S T A L L A T I O N S

3.1 PLANNING PERMISSION AND LICENCES

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.

3.2 LOCATION, SECURITY AND PHYSICAL PROTECTION OF EQUIPMENT

3.2.1 Non-public access installations on private property sites

3.2.1.1 General

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) specific equipment enclosures with sufficient lockable access doors/panels to provide

satisfactory access for inspection, maintenance and repair; or

(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.

NOTE: This requirement may be satisfied by the overall site boundary fence provided it

affords the same level of protection.

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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

STORAGE MINIMUM SEPARATION DISTANCES

Items from which separation is

required

Aggregate gas capacity of storage (m3)

(see Note 2)

Minimum separation

distances (m)

≤150 See Note 3

>150 ≤600 3

>600 ≤2 500 6

>2 500 ≤10 000 8

Property boundary/public place or

protected place

>10 000 To be determined by risk

analysis

≤150 3

150 ≤600 3

>600 ≤2 500 5

>2 500 ≤10 000 8

Stores of other dangerous goods

>10 000 To be determined by risk

analysis

NOTES:

1 All gas volumes expressed in the above table are at 15°C, 101.325 kPa absolute pressure.

2 The minimum separation distances for aggregate capacities up to 600 m3 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.

3 As determined according to AS/NZS 60079.10.1 or 2 m whichever is the greater.

3.2.1.3 Gas compression equipment, dispensers/fill posts and all vents

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.

NOTE: AS/NZS 60079.10.1 provides guidance on measurement of separation distances.

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TABLE 3.2

DISPENSER MINIMUM SEPARATION DISTANCES

Minimum distances (m)

Items from which separation is required From the exterior surfaces

of the dispenser/fill post

From the associated Zone 2

hazardous areas as per

AS/NZS 60079.10.1

Property boundary/public place Hazardous area distance to be

used

0 (see Note 1)

On site ‘protected place’

– Buildings Hazardous area distance to be

used

0

– Openings in buildings Hazardous area distance to be

used

0 (Note 1)

– Combustible material storage, above ground

flammable liquid or LPG tank

Hazardous area distance to be

used

3

– Fixed ignition source Hazardous area distance to be

used

0 (Note 1)

Elements of the refuelling station

– Compressed gas storages 3 (see Note 2) N/A

– Other refuelling station elements that are

hazard area compliant

0 N/A

– Other refuelling station elements

that are not hazard area compliant

Hazardous area distance to be

used

0

NOTES:

1 Where the hazardous area is defined as starting from the end of the refuelling hose.

2 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.

3.2.2 Public access sites

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

Where equipment is protected by a roof or canopy, such a roof shall be designed to

facilitate the dispersal of gas.

3.2.5 Fire protection

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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NOTES:

1 Attention is drawn to dangerous goods and OHS regulations relating to the requirements for

fire protection for gas storages.

2 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) No smoking: This sign may be accompanied by permanent floor marking delineating

the no smoking area.

(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) Hazchem: Signs for compressed natural gas storage systems (referred to as

Emergency Information Panel in the Australian Dangerous Goods Code).

(e) Refuelling instructions in accordance with Appendix C.

(f) Personal protective equipment requirements.

(g) Emergency instructions to be followed in case of a major gas leak or fire, including

site evacuation plans and contact details for equipment isolation and repair.

Emergency stop switches and isolation valves shall be clearly identified with signage.

3.3 REFUELLING STATION ELEMENTS

All components used in the construction of a refuelling station shall meet the requirements

of Section 2 of this Standard.

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) The gas compression equipment in accordance with Clause 3.5.

(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) A high pressure discharge system comprising the interconnecting piping/tubing,

valves and related components between the compressors, storage and dispensers in

accordance with Clause 3.8.

(f) Safety and control systems.

(g) The electrical system.

(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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3.4 INLET GAS SUPPLY EQUIPMENT

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) An isolating valve as specified in AS 5601.

(b) A non-return valve as specified in AS 5601.

(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) A pulsation damper to moderate compressor induced gas pulsations in accordance

with the requirements of the gas supplier. The combined volume of the inlet piping,

inlet damper vessel and any ancillary vessels shall be such as to limit the pressure rise

to less than the set pressure of the inlet gas equipment pressure relief valve, when the

compressor stops.

(f) A filter, as specified by the compressor manufacturer, with test connections for

pressure drop measurements.

(g) Additional isolating valves at each compressor where more than one compressor is

installed.

3.5 GAS COMPRESSION EQUIPMENT

Gas pressure equipment shall incorporate the following:

(a) The compressor(s) with interconnecting piping/hoses and associated fittings, gas

coolers, separators, separator drainage and blow down equipment, stage relief valves

and interconnecting pipework and valves in accordance with Clauses 2.3, 2.4, 2.5 and

2.6.

(b) The drive motor or engine.

(c) Instrumentation and control/protection devices in accordance with Clauses 2.3, 2.8

and 3.9.

Gas compression equipment may be located in sound attenuating and/or weather protecting

enclosures or on open skids.

The enclosures or skids may be mounted on anti-vibration mounts or bolted directly to

concrete foundations. Access doors and panels should be lockable if not located within a

locked enclosure in accordance with Clause 3.2.1.

Foundation design shall take into account both static and dynamic loads, compressor and

driver vibrations, and all relevant working and soil conditions.

The discharge from relief valves shall be piped to a vent stack in accordance with

Clause 3.8.2 either directly or indirectly via a connection to the inlet gas supply equipment.

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.

A non-return and isolating valve shall be fitted immediately downstream of the compressor

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3.6 COMPRESSED GAS STORAGE SYSTEMS

3.6.1 Static storage systems

Static compressed gas storage systems shall consist of the following:

(a) 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) A pressure gauge for each bank in accordance with Clause 2.7.

(d) A master shut off valve for each bank in accordance with Clause 3.8.3.

(e) Vent piping from safety devices where required by other Standards.

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

As a minimum, dispensers/fill posts shall include an assembly of the following components

in an enclosure or on open frame(s) or post(s) depending on location and purchaser

requirements:

(a) 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) A hose isolating valve, which shall be positioned to be readily accessible to the

person refuelling the vehicle.

(c) A fill pressure gauge.

(d) A pressure control device meeting the requirements of Clause 3.9.3 to be provided to

ensure that the vehicle gas containers are not filled to pressures above those for which

they are rated.

(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.

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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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.

3.7.2 Additional components

The following additional components may be incorporated as required by the purchaser:

(a) 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) A particle filter fitted as close as possible to the vehicle refuelling connector.

(d) Sequencing valves for optimizing gas storage utilization and vehicle filling in

accordance with Clause 3.9.4.

3.7.3 Slow fill stations

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.

Test connections shall be provided where pressure readings are desired for diagnostic

purposes.

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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

As a minimum, isolating valves shall be provided as follows:

(a) At the outlet of each compressor in accordance with Clause 3.5.

(b) At the outlet of each storage bank in accordance with Clause 3.6.

(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.

Additional isolating valves shall be provided as required to facilitate access to equipment

for maintenance and repair with bleed connections between isolating valves to depressurize

before access to components. Under no circumstance shall the highly dangerous practice of

undoing screwed or compression fittings be employed for this purpose.

3.8.3.2 Non-return valves

As a minimum, non-return valves shall be provided as follows:

(a) At the outlet of each compressor in accordance with Clause 3.5.

(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:

(a) Filtration of the gas stream to the extent required by the end user.

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(b) Damping pressure pulsations.

(c) Joining piping and tubing i.e. compression and face seal type joints.

(d) Connection blocks to facilitate multiple piping/tubing connections.

3.9 SAFETY AND CONTROL SYSTEMS

3.9.1 Safety devices for over pressure protection

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

As a minimum, each compressor shall be fitted with the following switches/devices

integrated into the control system in accordance with Clause 3.10.2:

(a) A pressure switch for low inlet pressure set as specified in AS 5601.

(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 manufacturer’s

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 manufacturer’s

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) A temperature switch for high hydraulic oil temperature.

(ii) A level switch for low hydraulic oil level.

3.9.3 Refuelling pressure control

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.

For fast fill systems without a temperature compensated pressure control system, the

maximum fill pressure shall be 20 MPa.

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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 15°C, 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.

Emergency stop switch(es) shall be provided at the dispenser(s) location(s) to work in

series with the compressor emergency stop(s).

NOTE: Emergency stop switch(es) may be required by the purchaser at other locations.

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S E C T I O N 4 T E S T I N G A N D C O M M I S S I O N 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.

4.2 STATION COMPLIANCE DOCUMENTATION

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) pressure vessel certificates;

(b) cylinder production test certificates;

(c) dispensing hose test certificates; and

(d) safety relief valve certificates and other equipment test results relevant to

commissioning.

4.4 COMMISIONING DOCUMENTATION AND RECORDS

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.

Records of tests and commissioning shall be kept.

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S E C T I O N 5 O P E R A T I O N A N D

M A I N T E N A N C E

5.1 GENERAL

Refuelling stations shall be operated and maintained—

(a) when all necessary inspections, licences and certification are current;

(b) within the design parameters established for construction; and

(c) when all fitted control and safety devices are functioning correctly.

Attention is drawn to the need to comply with OHS requirements.

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.

5.2 ESTABLISHMENT OF PROCEDURES

5.2.1 Procedures required

Procedures shall be appropriate to the station as follows:

(a) Operating procedures shall cover all aspects of the facility.

(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.

5.2.2 Promulgation of procedures

The procedures shall be documented in notices, manuals, or other recorded instructions as

appropriate to the particular station. They shall be on view or readily available on site.

5.2.3 Review and upkeep of procedures

The procedures shall be modified to reflect equipment or organizational changes.

5.2.4 Operating procedures

The operating procedures shall take into account the following, as appropriate to the

particular station:

(a) Normal handling procedures, with refuelling procedures in accordance with

Appendix C.

(b) The monitoring of essential functions and components.

(c) Recognition of fault conditions.

(d) Housekeeping and site upkeep.

(e) Treatment of leakage.

(f) For equipment, any manufacturer’s operating instructions. Acc

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(g) The maintenance of clear spaces for access.

(h) Personnel safety.

(i) Personal protective equipment.

(j) Control of ignition sources.

(k) Control of access and security.

(l) Vehicle movement.

5.2.5 Maintenance procedures

Maintenance procedures shall take into account the following, as appropriate to the

particular station:

(a) Regular testing of protective devices, alarms and emergency stop systems.

(b) Establishment of safe areas.

(c) Gas purging.

(d) Isolation and tagging.

(e) Control of contractors.

(f) Work authorization.

(g) Firefighting equipment.

(h) Pipelines.

(i) Gas containers (pressure vessels).

(j) Draining and separators.

(k) Electric equipment.

(l) Ventilation systems.

(m) Fences and security measures, signs, and notices.

(n) Illumination.

(o) The needs of any other individual items or plant components, taking into account any

manufacturer’s maintenance instructions.

5.2.6 Emergency procedures

Emergency procedures based on emergency planning, such as those detailed in AS 4332,

shall take into account the following, as appropriate to the particular station:

(a) List of contacts, emergency services and phone numbers.

(b) Chain of command.

(c) Duty list.

(d) Co-operation with relevant authorities.

(e) Fire teams (initial response).

(f) Debriefing and reporting.

(g) Contractors.

(h) Site plan.

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5.2.7 Training of personnel

5.2.7.1 Operational staff

Operational staff shall be trained in the following, as appropriate to the site:

(a) The properties, characteristics and hazards of any materials kept or handled.

(b) The correct use of any necessary personal protective equipment provided.

(c) Hazards likely to be encountered.

(d) The procedures to be followed in the event of an incident (leakage, accident or fire).

(e) The layout of the station.

(f) The location of firefighting equipment.

(g) The basic principles of firefighting, and the use of fire extinguishers.

(h) Any regulations relevant to their tasks.

(i) Area housekeeping.

(j) The safety rules of the station.

(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

Visitors to any refuelling station shall—

(a) 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.

5.2.7.3 Refresher training

Training procedures shall be repeated at sufficient intervals to ensure that capability is

maintained.

5.3 SUPERVISION

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

Records shall be kept of—

(a) training and retraining;

(b) routine inspection and testing of equipment in accordance with Clause 5.6; and

(c) abnormal incidents, including near-miss occurrences.

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5.5 SPECIFIC OPERATING PROCEDURES

5.5.1 Commissioning new or modified equipment

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

Safety inspections shall be conducted at monthly or longer intervals depending on the

extent of use as indicated by compressor hours run.

Attention is drawn to the need to comply with regulations should these specify inspections

at shorter intervals than indicated above.

5.6.2.2 Fixed time interval inspections

In addition to routine inspections as required by Clause 5.6.2.1, annual inspections shall be

conducted by a suitably qualified person(s) in relations to the following:

(a) 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.

In addition, inspections shall be conducted by a suitably qualified person(s) in relation to

the following:

(i) Emergency stop systems shall be tested at frequencies as established in accordance

with Clause 5.2.5(a) but in any event not less than annually.

(ii) Electrical equipment shall be inspected in accordance with the relevant Australian

Standards.

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. Acc

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5.6.2.3 Gas containers

Periodic inspection and testing shall be completed as specified in—

(a) AS 2030.1 for cylinders; or

(b) AS/NZS 3788 for pressure vessels.

5.6.2.4 Safety relief devices

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) Exercising care in handling and storage to prevent plugging of openings by the

accumulation of extraneous matter such as paint and dirt.

(c) Replacing damaged or malfunctioning assemblies with serviceable safety relief

devices.

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

Fire protection equipment shall be inspected and maintained at intervals as required by

AS 1851.

5.6.2.6 Records

A record of the inspection shall be maintained.

5.6.3 Authorization of work

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) A verbal instruction, which shall be limited to authorization of non-hazardous actions.

(b) A written procedure, to deal with a standardized and repetitive normal activity.

(c) A work permit, to deal with potentially hazardous activities requiring close attention.

5.6.4 Work permit

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) The period for which it is valid.

(b) The nature and extent of the work.

(c) Any conditions and precautions to be observed.

(d) Any protective equipment or clothing to be used.

(e) Any preparatory work necessary to ensure that it is safe to start work. Acc

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(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) Any firefighting equipment required.

NOTE: A sample work permit is illustrated in Appendix E.

5.6.5 Safe procedures

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) Any written safety procedures shall be followed.

(b) Protective devices shall not be removed unless substitute protection has been

provided.

(c) Inadvertent operation during maintenance shall be prevented.

(d) Contamination of equipment by water, dirt, foreign matter, or other materials shall be

prevented.

5.6.6 Preparation of work site

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) Identification of both the equipment to be worked on and all other equipment

affected, including underground piping or equipment.

(b) Depressurization and disconnection.

(c) Isolation from other equipment.

(d) Blanking or capping opened connections.

(e) Removal of combustible materials.

(f) Provision of additional protection, fire guards and firefighting equipment.

(g) Testing for flammable gas and oxygen levels.

5.6.7 Completion of work

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) the work has been completed;

(b) any temporary arrangements have been discontinued, e.g. bypass lines or blank

flanges have been removed, fuses replaced;

(c) all personnel and equipment are accounted for; and

(d) the work permit is cancelled.

5.6.8 Hot work

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.

NOTE: For an example, see Appendix E.

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5.6.9 Routine work

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 gas-containing equipment having approval as a pressure component shall not be

modified until approval for the modification has been obtained from the Technical

Regulators.

5.6.11 Work within hazardous areas

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.

In particular—

(a) the area shall be kept clear of all extraneous material;

(b) specified clearance distances shall be maintained;

(c) vegetation that might become a fire hazard shall be kept clear;

(d) the surface coating of tanks shall be maintained in good condition;

(e) signs and notices shall be kept in a legible condition; and

(f) lighting shall be kept operational and effective.

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APPENDIX A

REGULATORY AGENCY INFORMATION

(Informative)

The following information is for guidance only and may be subject to change:

Federal,

State or

Territory

Function Authority Contact Address Phone Fax

Federal Dispenser meter

approval

National

Measurement

Institute

Bradfield Road

Lindfield NSW 2070

(02) 8467 3600 (02) 8467 3610

Dangerous goods

transport and

storage, CNG

storage cylinders

ACT WorkCover Chief Inspector of Dangerous

Goods

PO Box 224

Civic Square ACT 2608

(02) 6207 6355 (02) 6207 7249

Gas technical

regulation

ACT Planning and

Land Authority

PO Box 1908

Canberra ACT 2601

(02) 6207 1923

(callers outside

ACT/NSW)

or

13 22 81

(calls within

ACT/NSW)

—

Australian

Capital

Territory

CNG dispenser

metering

Trade Measurement

Unit, ACT Office of

Fair Trading

255 Canberra Avenue

Fyshwick ACT 2609

(02) 6207 0400 —

Dangerous goods

storage

WorkCover NSW Dangerous Goods Inspector

(Professional)

PO Box 1476

Parramatta NSW 2124

(02) 9841 8449

Gosford general

enquiries:

(02) 4321 5000

(02) 9687 6712

Dangerous goods

transport and all

other matters

NSW Department of

Environment and

Conservation

Manager

Dangerous Goods

PO Box A290

Sydney South NSW 1232

(02) 9995 5555

or

131 555

Environment Line

(within NSW)

(02) 9995 5918

Gas technical

regulation

Department of

Water and Energy

GPO Box 3889

Sydney NSW 2001

(02) 8281 7777 (02) 8281 7799

New South

Wales

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

Chief Dangerous Goods

Inspector

GPO Box 4821

Darwin NT 0801

(08) 8999 5140 (08) 8999 5141 Northern

Territory

CNG dispenser

metering

Trade Measurement,

Department of

Justice

— (08) 8922 0866 —

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Federal,

State or

Territory

Function Authority Contact Address Phone Fax

Dangerous goods

transport

Queensland

Transport

Principal Engineer

(Dangerous Goods)

PO Box 673

Fortitude Valley QLD 4006

(07) 3253 4606 (07) 3253 4453

Dangerous goods

storage

Workplace Health

and Safety

Queensland

Department of

Industrial Relations

PO BOX 69

Brisbane QLD 4001

(07) 3225 2000 (07)3225 1540

Gas technical

regulation

Department of

Natural Resources,

Mines and Energy

Petroleum and Gas

Operations Branch

GPO Box 2454

Brisbane QLD 4000

(07) 3237 1415 (07) 3235 4395

Queensland

CNG dispenser

metering

Trades and

Measurements

Section - Office of

Fair Trading,

Department of

Tourism and Fair

Trading

— (07) 3115 1770 —

Dangerous goods

transport and

storage

Safework SA

Department of the

Premier and Cabinet

Manager

Dangerous Substances

GPO Box 465

Adelaide SA 5001

(08) 8303 0400 (08) 8226 4999

Gas technical

regulation

The Office of the

Technical Regulator

Department of

Transport , Energy

and Infrastructure

Principal Gas

Advisor/Engineer

Level 8 ANZ Building (City

Central Tower 1)

11 Waymouth Street

Adelaide SA 5001

(08) 8226 5500

(08) 8226 5866

South

Australia

CNG dispenser

metering

Trade Measurements

Branch, Office of

Consumer and

Business Affairs

— (08) 8234 2036 —

Tasmania Dangerous goods

transport , storage

and gas technical

regulator

Workplace

Standards Tasmania

General Manager

PO Box 56

Rosny Park TAS 7018

(03) 6233 8366 (03) 6233 8338

Dangerous goods

transport and

storage

Victorian

Workcover

Authority

Manager

Dangerous Goods

GPO Box 4306

Melbourne VIC 3001

(03) 9641 1551 (03) 9641 1552

Gas technical

regulation

Energy Safe Victoria PO Box 262

Collins St West VIC 8007

(03) 9203 9700 (03) 9686 2197

Victoria

CNG dispenser

metering

Trade Measurement,

Office of Fair

Trading

— (03) 8684 6280 —

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Federal,

State or

Territory

Function Authority Contact Address 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

Cloister’s Square WA 6850

(08) 9358 8002 (08) 9358 8188

Gas technical

regulator

Energy Safety

Division

Department of

Commerce

Chief Gas Inspector

Energy Safety Division

303 Sevenoaks Street

Cannington WA 6107

or

PO Box 135

Cannington WA 6987

(08) 9422 5200 (08) 9422 5244

Western

Australia

CNG dispenser

metering

Trade Standards

Branch, Department

of Commerce

Manager

Trading Standards Branch

321 Selby Street

Osborne Park WA 6017

or

Locked Bag 14

Cloister’s Square WA 6850

(08) 9282 4300 (08) 9282 4301

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APPENDIX B

TYPICAL LAYOUT OF MOBILE STORAGE UNITS

(Informative)

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APPENDIX C

REFUELLING INSTRUCTIONS AND PROCEDURES

(Normative)

C1 BEFORE REFUELLING

It is the responsibility of the refueller to ensure the following:

(a) The CNG vehicle identification labels are approved and on the vehicle registration

plates.

(b) There is no smoking of cigarettes or any naked flame within 3 m of the vehicle.

(c) The vehicle handbrake is firmly applied and the vehicle parked in gear or ‘P’ (with

automatic transmission).

(d) The engine is switched off.

(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) There are no leaks.

C2 REFUELLING PROCEDURE

The refuelling procedure shall be as follows:

(a) Remove dust cap from refuelling receptacle.

(b) Ensure that the refuelling receptacle is in good condition.

(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.

On completion of refuelling, whether occurring automatically or manually—

(i) follow the site specific instructions displayed, remove refuelling nozzle from the

vehicle refuelling receptacle and return the refuelling hose to its rest position;

(ii) check that there are no leaks; and

(iii) replace dust cap on the vehicle refuelling receptacle.

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APPENDIX D

CHECKLIST FOR PUTTING THE STATION INTO SERVICE AND ANNUAL

SAFETY INSPECTIONS OF REFUELLING STATIONS

(Informative)

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 Tick Clause reference/

details/comments

Approvals and compliance documentation

Have all approvals been obtained? 3.1

Has the station contractor provided a statement of compliance with this

Standard and provided a list of minor deviations?

4.2

Location, security and protection

Have the hazardous areas created by the presence of the refuelling

station been established?

3.1 and 3.2

Are the separation distances observed as required by Standards? 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

Is the station adequately protected from damage by vehicle collisions? 3.2

If refuelling is to take place after dark, is the dispenser area adequately

illuminated?

3.2.6

Is there provision to secure dispensers/fill posts from unauthorized use

when the site is not manned?

3.2 and 3.7.1

Are dispenser operation and filling instructions displayed? 3.2.7

Is firefighting equipment to this Standard in place? 3.2.5

Are required safety signs in place? 3.2.7

Inlet Gas supply (see also Section 5)

Has the Technical Regulator been made aware of the intended station

of a gas pressure raising device?

3.4 (see also AS 5601)

High pressure gas storage systems

Is the certificate of all cylinders current and certificates provided? 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

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Item Tick Clause reference/

details/comments

Has the presence of all pressure vessels been registered? 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

Has the Technical Regulator been made aware of the station? State and territory

requirements regarding

‘notification of Electrical

work’

Has a hazardous area dossier been provided establishing compliance

with electrical standards for hazardous area service?

5.6.2.2 (see also

AS/NZS 2381.1)

Has the station been inspected and permission to energize given? As required by state and

territory authorities

Testing and commissioning

Has the station been inspected and permission to commission given? 3.1, 4.4

Has the commissioning been witnessed and permission to operate

given?

3.1, 4.4

Has commissioning been completed in accordance with this Standard

and the test and commissioning records provided?

4.4

Operation and maintenance

Have procedures been established for operation, maintenance

emergency responses, training, visitors, supervision, work permits and

records?

5.2

Has the operational staff been trained with arrangements for refresher

training at intervals?

5.2.7

Have the site emergency procedures been amended to reflect the

presence of the refuelling station and the Fire Brigade informed?

5.2.6

Have arrangements been made for periodic safety and annual

inspections?

5.6

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AS 5092—2009 40

© Standards Australia www.standards.org.au

APPENDIX E

HOT WORK PERMIT

(Informative)

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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 Australia’s 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 Australian Standards® 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. International Involvement Standards Australia is responsible for ensuring the Australian viewpoint is considered in the formulation of International Standards and that the latest international experience is incorporated in national Standards. This role is vital in assisting local industry to compete in international markets. Standards Australia represents Australia at both the International Organization for Standardization (ISO) and the International Electrotechnical Commission (IEC). Sales and Distribution Australian Standards®, Handbooks and other documents developed by Standards Australia are printed and distributed under license by SAI Global Limited.

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For information regarding the development of Standards contact: Standards Australia Limited GPO Box 476 Sydney NSW 2001 Phone: 02 9237 6000 Fax: 02 9237 6010 Email: mail@standards.org.au Internet: www.standards.org.au For information regarding the sale and distribution of Standards contact: SAI Global Limited Phone: 13 12 42 Fax: 1300 65 49 49 Email: sales@sai-global.com

ISBN 0 7337 9260 X

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