CNG, LNG, and LPG in Repair and Maintenance Facilities: Code Issues and Compliance

> February 2014

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Safety Facility Audit Code Requirements Modifications Resources

Identify Objectives &

Codes

Natural Gas Overview

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Safety

Hazards• High Pressure Natural Gas (CNG)• Ignition Sources – Fire (CNG & LNG) • Noise Produced During Depressurization (CNG)• Cryogenic Burns (LNG)• Asphyxiation (CNG & LNG)

Precautions• Personal Protection Equipment (PPE)• Proper Grounding and Venting Procedures per IFC and

NFPA• Facility Modifications per code

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Objectives and Codes

Objectives for Garage Owner/Personnel• Identify requirements for different types of AFVs to be serviced• Code compliant & safe shop

Codes and Standards referenced in this presentation (applicable C&S will vary by jurisdiction)

• International Fire Code (IFC 2009)• International Building Code (IBC 2009)• International Mechanical Code (IMC 2009)• NFPA 30A – Code for Motor Fuel Dispensing Facilities and Repair

Garages (2012)• NFPA 52 – Vehicular Gaseous Fuel Code (2013)• NFPA 70- NEC: Article 511 (2011)

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Facility Audit

Determine type of work performed/expected• Major- modifications to existing facility are required• Minor- exempt from most modifications required to

accommodate CNG or LNG vehicles

Code compliance of existing facility• For existing conventional fueled vehicle work and

activities (IFC, IBC, & IMC or NFPA)• Involvement of Authority Having Jurisdiction (AHJ) &

establish which codes are accepted

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Code Requirement- Major vs. Minor

Major vs. Minor Repair Activities:

Hazard Separation• With proper separation, only major repair areas

require modification per code

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Code Requirements- Ventilation

Mechanical Ventilation Requirements:

*allows for non-continuous ventilation with proper gas detection

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Code Req. -Electric Classification

Electrical & Hazardous Area Classification:• Hazardous area classification can be avoided by supplying

continuous ventilation per NFPA 30A and 70

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Code Req. -Electric Classification

Electrical & Hazardous Area Classification:• Hazardous area classification can be avoided by supplying

continuous ventilation per NFPA 30A and 70

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Code Topic – Gas Detection

Gas Detection is not required by code for odorized CNG applications however it can reduce ventilation operating cost Gas Detection (when installed):

• System designed to identify flammable gas mixtures in excess of 25% of LFL

• Activation shall (NFPA 30A, Chapter 7):1. Initiate audible and visual alarms2. Turn off garage heating elements3. Turn on emergency ventilation if interlocked

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Code Topic – Gas Detection

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Code Req. – Heat Producing AppliancesHeat Producing Appliances:

•Gas or oil fueled heaters must be install 18” above grade for conventional fuel repair garages.

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Code Requirements – Vehicle Prep

Preparation for Vehicle Repair, Inspection, and Defueling• IFC 2211.5 requires CNG cylinder and LNG tank valves to

be closed, damaged vehicles must be inspected including performing a leak check.

• NFPA 52: 6.12.4 (and Appendix A.6.12.4) recommends similar practices prior to repair and service.

• Several new requirements in NFPA 52, ed. 2013, 6.13 and 6.14

• NFPA 52: 6.13 Inspections shall be performed per the container label and the vehicle or container manufacturer’s instructions.

• NFPA 52: 6.14 Repair garages should provide a proper defueling post/tube.

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Steps to Determine if Garage Modifications are Necessary

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Resources

• Guideline for Determining the Modifications Required for Adding Compressed Natural Gas and Liquefied Natural Gas Vehicles to Existing Maintenance Facilities, Horne, Douglas B., Clean Vehicle Education Foundation, August 31, 2012 (http://www.cleanvehicle.org/committee/technical/PDFs/GuidelinesDocumentFinal.pdf)

• Wisconsin State Energy Office: Natural Gas for Transportation Vehicle Repair Garage Guidelines (http://www.stateenergyoffice.wi.gov/docview.asp?docid=24889&locid=160)

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Resources Cont. - Illinois

Identifying which Codes apply in Illinois: • There is no unifying building code(s) for the state nor

overarching state funded buildings department• The state website has a listing of codes required by

village and county -http://www.illinois.gov/cdb/business/codes/Pages/BuildingCodesRegulations.aspx

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Resources Cont. - Wisconsin

Identifying which Codes apply in Wisconsin:Wisconsin Department of Safety and Professional Services, Commercial Building Program: • Administrative Code SPS 361 establishes building codes for

the state which include IBC (2009) & IMC (2009).• The state also recognizes International Existing Building

Code (2009) that may affect retrofitted structures.• SPS 361.03 (14) does not recognize IFC chapter 22: Motor

Fuel-Dispensing Facilities and Repair Garages• http://dsps.wi.gov/Default.aspx?Page=80b145e2-4b29-

46f9-a7aa-047009b0342f• SPS 316 recognizes NEC/ NFPA 70 2008 for electrical

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Resources Cont. - Indiana

Identifying which Codes apply in Indiana:Indiana Fire Prevention and Building Safety Commission: • Administrative Code 675 IAC establishes building codes

for the state which include Indiana Building Code 2008 Article 12 (based on IBC 2006), Indiana Fire Code 2008 Article 22 (based on IFC 2006) & Indiana Mechanical Code 2008 Article 18 (based on IMC 2006).

• State of Indiana recognizes its own Indiana Electrical Code 2009 (based on NEC/NFPA 70 2008)

• http://www.in.gov/dhs/2490.htm

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Natural Gas Key Takeaways

• Major vs. Minor Repairs drive requirements• Separation of Major Repair Bays can minimize

modifications• Gas Detection is not required for CNG but it can

reduce ventilation operating cost • Proper Procedures and Training are key

• Preparation for Vehicle Repair, Inspection, and Defueling

• Understanding of high pressure gas• Certified, trained technicians

2020

Safety Facility Audit Code Requirements Modifications Resources

Identify Objectives &

Codes

Propane Overview

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SafetyPhysical Characteristics

• NFPA Class IA Flammable Liquid • Volatility – LPG at atmospheric pressure will change phase from liquid

to vapor• Propane in vapor state is 1.5 x heavier than air

Hazards• Ignition Sources – Fire• Asphyxiation

Precautions• Personal Protection Equipment (PPE)• Proper Safety Procedures • Facility Modifications (if required)

2222

Objectives and Codes

Objectives for Garage Owner/Personnel• Code compliant & safe shop

Codes and Standards referenced in this presentation (applicable C&S will vary by jurisdiction)

• International Fire Code (IFC 2009)• International Building Code (IBC 2009)• International Mechanical Code (IMC 2009)• NFPA 30A – Code for Motor Fuel Dispensing Facilities and

Repair Garages (2012)• NFPA 58 – Liquefied Petroleum Gas Code (2013)• NFPA 70- NEC: Article 511 (2011)

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Facility Audit

Determine type of work performed/expected• Major v. Minor- for code compliance (NFPA 30A and IFC)

for existing facility

Code compliance of existing facility• For existing conventional fueled vehicle work and

activities (IFC, IBC, & IMC or NFPA)• Involvement of Authority Having Jurisdiction (AHJ) &

establish which codes are accepted

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Code Requirement- Major vs. Minor

Major vs. Minor Repair Activities:

• Includes associated floor space used for offices, parking, and/or showrooms.

• Assuming no fuel will be stored or transferred in garage

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Code Requirements- Ventilation

Mechanical Ventilation Requirements:

• There are no additional ventilation requirements for LPG facilities

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Code Req. -Electric Classification

Electrical & Hazardous Area Classification:

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Code Req. – Sources of Ignition

Source of Ignition:•A major concern of ignition source in repair garages is space heater design.

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Code Requirements – Vehicle Prep

NFPA 58 addresses requirements for indoor parking and vehicle repairs.

• The code differentiates between public and owner operated repair facilities.

9.7.3.5 & 6: Prior to repair in a private repair ship:• Repair Facility should be built in accordance to NFPA 58 Chap 10• Public shall be excluded from shop areas• Floor level ventilation is required• Leaks in system should be repaired• Tank valves should be closed• Vehicle tanks can not be in direct path of heated air supply• Amount of fuel is limited to max. capacity stated in NFPA 58 Section 7.4

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Code Requirements – Vehicle Prep

9.7.3.6: Prior to repair in a public repair shop:• Operator shall be in attendance at all times while vehicle is

indoors• Leaks in system should be repaired• Tank valves should be closed• LPG should be removed from piping, pump, meter, and

delivery hose• Pressure must be equalized with atmospheric• Vehicle tanks can not be in direct path of heated air supply• Amount of fuel is limited to maximum filling capacity stated in

NFPA 58 Section 7.4

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Steps to Determine if Garage Modifications are Necessary

Facility Audit

• Is the existing facility code compliant? • Are shop activities minor or major?• Is the shop public or private?

Codes• What codes will the AHJ use for compliance and inspection?

Shop Mods

• Ventilation• Hazardous Area Classification• Sources of Ignition• Defueling System and Vehicle Prep Procedures

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Resources

Additional Reading:• Propane Autogas: Repair and Maintenance Facility

Requirements, Propane Education & Research Council (PERC), 2013.

(http://www.autogasusa.org/uploadedFiles/Fuel/Resources/Training_Manuals/Repair_and_Maintenance%20Facility_Requirements.pdf)

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Resources Cont. - Illinois

Identifying which Codes apply in Illinois: • There is no unifying building code(s) for the state nor

overarching state funded buildings department• The state website has a listing of codes required by

village and county -http://www.illinois.gov/cdb/business/codes/Pages/BuildingCodesRegulations.aspx

3333

Resources Cont. - Wisconsin

Identifying which Codes apply in Wisconsin:Wisconsin Department of Safety and Professional Services, Commercial Building Program: • Administrative Code SPS 361 establishes building codes for

the state which include IBC (2009) & IMC (2009).• The state also recognizes International Existing Building

Code (2009) that may affect retrofitted structures.• SPS 361.03 (14) does not recognize IFC chapter 22: Motor

Fuel-Dispensing Facilities and Repair Garages• http://dsps.wi.gov/Default.aspx?Page=80b145e2-4b29-

46f9-a7aa-047009b0342f• SPS 316 recognizes NEC/ NFPA 70 2008 for electrical

3434

Resources Cont. - Indiana

Identifying which Codes apply in Indiana:Indiana Fire Prevention and Building Safety Commission: • Administrative Code 675 IAC establishes building codes

for the state which include Indiana Building Code 2008 Article 12 (based on IBC 2006), Indiana Fire Code 2008 Article 22 (based on IFC 2006) & Indiana Mechanical Code 2008 Article 18 (based on IMC 2006).

• State of Indiana recognizes its own Indiana Electrical Code 2009 (based on NEC/NFPA 70 2008)

• http://www.in.gov/dhs/2490.htm

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Propane Key Takeaways

• Is the existing facility code compliant for traditional fuels?• LPG facility compliance is similar to traditional fuel

compliance (ventilation, electrical classification, sources of ignition)

• Proper Procedures and Training are key• Preparation for Vehicle Repair, Inspection, and

Defueling (NFPA 58 – 9.7.3.6)• Understanding of high pressure gas• Certified, trained technicians

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Acknowledgement of Support

FEBRUARY 5, 2014WISCONSIN CLEAN CITIESWEBINAR

Steve Arnold, P.E.Senior Design Manager

NGV MAINTENANCE FACILITIESCode Related Modifications For NGVs In Existing Maintenance Facilities

TODAYS AGENDA

Wisconsin specific requirements and compliance strategies

Case Studies Costs Q&A

ET ENVIRONMENTAL First CNG project

completed in 2004 Over 90 fueling projects

completed Team dedicated to turn-key

CNG projects• Design staff – 18• Construction staff – 40• 40+ projects in progress

12 offices

SEO Guidelines Document Background

• State outreach programs identified a barrier to growth of the NGV market

Purpose• Provide industry guidance on maintenance shop code and

safety requirements• Encourage consistent code interpretation

Document Development• In coordination with SEO, DSPS, Fire Officials, and Fleet

Owners

WI Applicable Codes

Partial list of codes and standards: National Fire Protection Association (NFPA)

• NFPA 30A Code for Motor Fuel Dispensing Facilities and Repair Garages

• NFPA 70 National Electric Code (NEC)• NFPA 52 Vehicular Gaseous Fuel Systems Code

I-Codes – IBC, IMC, IFC, IEBC Municipal / Local requirements and amendments

MAINTENANCE FACILITESGARAGE RETROFITS FOR NGVs

Every shop is unique Consult a professional Code compliance is only

one component• Operations• Training

NGV MAINTENANCE FACILTY EVALUATION

1) Ventilation2) Gas Detection3) Heating Systems4) Electrical Systems and Components

Existing Conditions and Code Triggers Other items that may be applicable(for now, assume “Major Repair Garage”)

NGV MAINTENANCE FACILITYVENTILATION

TWO DISTINCT VENTING CRITERIA1) PURGE VENTING

• Only required for NGV’s, not Diesel or Gasoline Vehicles

2) AIR QUALITY FOR OCCUPIED SPACES

• Same for Natural Gas, Diesel, and Gasoline .

• WI revision SPS 364 (0.5 cfm/sf)

NGV MAINTENANCE FACILITYVENTILATION

Compliance Requirements:• Airflow - low to high• 5 air changes per hour (ACH)• 3 ways to operate

Compliance Strategies:• Roof mounted fans• Makeup air• Hazardous environment rating• # and location of fans

Detector heads – where and how many? Tied to a fire alarm system or monitoring? Calibration Relay Panel LNG

NGV MAINTENANCE FACILITYDETECTION

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NGV MAINTENANCE FACILITYHEAT & FLAMES

Areas of ignitable concentrations Non-compliant heaters Other non-compliant appliances Compliant heat

• Floor Radiant• Low Intensity

Radiant• Air handler*• Steam

NGV MAINTENANCE FACILITYHEATERS

NGV MAINTENANCE FACILITYELECTRICAL

Classified Zone “the area with 18” of the ceiling shall be designated a Class 1, Division 2 hazardous location ………

Except in WisconsinRef SPS 316.511effective Dec 1, 2013

NGV MAINTENANCE FACILITYADJACENT OCCUPANCIES

“Enclosed rooms for [NGVs] … should prohibit the transmission of gases to other areas of the building.”Compliance Strategies: Positive pressure in adjacent

occupancy Separation wall sealed to

prevent transmission of gas

ADDITIONAL ITEMS TO CONSIDER

Floor Drains• Provisions should be made to prohibit LNG from

entering a closed drain conveyance system or oil water separator.

LNG Venting• Parking/Maintenance of LNG vehicles indoors

Existing Building & Conditions WI has adopted the

2009 IEBC

Identify “triggers” for current code compliance

Alteration Level and Change in Occupancy

Existing Buildings & Conditions Building Alteration Level 2 is common Change of Occupancy is applicable. = change in level of

activity that involves a change in the application of the code

Must comply with new code provisions specifically for NGVs

Energy Conservation – amended by SPS 366.0607….unaltered portions not required to comply with energy codes

Structural – 5% rule Fire Protection – Automatic Sprinkler “Triggers”

NGV MAINTENANCE FACILITYHEAT

< 750 °F and no open flames

VENTILATIONRequired at 5 ACH

Interlocked to LightingCNG Only (NA tot LNG)

Continuous Interlocked to Gas Detection

GAS DETECTION

Gas Detection required for LNG

Electrical classified areas must be addressed for projects outside of Wisconsin

MINOR REPAIR GARAGESMINOR REPAIR GARAGE = lubrication, inspection, tune-ups, replacement of parts, fluid changes, brakes, tires, and similar routine maintenance

NGV Minor Repair Garages are exempt from many but not all of the code provisions.

MINOR REPAIR GARAGES Electrical – Ceiling Classified Areas

• Exempt, ceiling is “unclassified” Heating and Sources of Ignition

• Exempt from 750 ° F and open flame requirement Ventilation

• 5 ACH required by International Mechanical Code• “Petition for Variance” may be a method of compliance

Gas Detection • Required for LNG• May be used for ventilation controls (CNG)

MINOR REPAIR GARAGESElectrical - Ceiling Unclassified

HeatNo 750 °F and open flame requirements

Ventilation - Required at 5 ACH(or petition for a variance)

Interlocked to lightingCNG Only (NA to LNG)

Continuous Interlocked to Gas Detection

Gas Detection required for LNG

Wisconsin Permitting State and/or Local reviews required from both the

Building and Fire AHJ

Permitting Flow charts are available in the SEO guidelines document

NGV MAINTENANCE TRAINING & OPERATIONS

Training• Understanding of gas properties & hazards• O&M of systems• Respect the pressure

Develop standard operating procedures (SOPs)• Preparation of vehicle for service• Hot work in NGV shop- Prohibit torches, welding and

grinding near fuel system• Run LNG vehicles prior to entering the shop ( hold time)• Fuel Tank Inspections• Gas Detector Calibration

CASE STUDIES Reviewed 4 examples in the state of WI All 4 used different means of compliance

Frito Lay 3 bay Minor NGV Repair Continuous ventilation while occupied Sealed separation walls Adjacent indoor fueling bay

CASE STUDIESWaste and Recycling Vehicle Garage 7 bay Major repair garage Gas detection Purge venting Infrared Heating

Electrical rated for Classified area at ceiling

Sealed Separation walls at office and wash bay

CASE STUDIESKwik Trip Separated 1 Bay Major NGV Repair & LNG, Gas detection Purge venting Compliant Heating Electrical removed ceiling Plugged floor drain Additional lighting

CASE STUDIESCity of Milwaukee Separated 6 Bays Major Repair for NGVs Partition Walls Gas detection Purge venting Air handler heating Lighting rated for classified area

COSTS Cost information is presented in the guidelines

document. Costs are generic and qualified but should be useful in

getting a rough idea. Based on a 4 to 10 truck bay garage. Start with an initial assessment and method of

compliance. Determine # of bays to be retrofitted for NGVs. Not intended to replace qualified estimates. More cost information is in the guidelines document

COSTS Cont.

Ventilation $

Exhaust fans EA $8,200 - $9,200 Ventilation required for 5 ACH. Includes Mechanical, Electrical, Roof Framing & Roofing Work.

Ducting LF $45-$60 Exposed non-insulated interior duct & fittings

Assessment and Design $

Professional Services

LumpSum

$25,000 - $40,000 Assessment, Design, Permitting, & Construction Support

Some examples of cost information ……

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COSTS Cont.

Heating $

Infrared Tube heaters

$/SF $12-$17 Includes electrical

Gas Detection $

Detectors and Controller

1 $30,000-$45,000 Equipment, installation, and electrical.

LNG – Pit Detectors

EA $3,500-$5,000 Dependent on floor slab and underground scope of work.

COSTS Cont.Electrical $

Shunt Trip 30A Breakers

EA $525- $650 Assumes that space is available in the panel

Other $

Separation Wall SF $18 - $25 Metal Stud with metal panelsDesign Management

5% to 10% Schematic, design mgmt, permitting, permit fees

COSTS Cont. Other cost items are addressed in more detail in

the guidelines document.• Misc Demolition• Lighting• LNG Floor Drains• Roof Access Ladder

Cost Saving Strategies Use a sealed partition wall to separate NGV repair

areas Hire experienced design professionals and

contractors Select HVAC system considering operational

costs Seek out financial incentives (WI Focus on

Energy program, grants, etc.) + more ideas in the guidelines document

QUESTIONS?

Steve Arnold, P.E.Senior Design Manager

Contact Information

ET Environmental Corporation, LLCWebsite: www.etenv.com

Steve Arnold Jeff Lamoureuxsarnold@etenv.com jlamoureux@etenv.com708-478-8200 208-928-7361

Wisconsin Department of Administration - State Energy OfficeWebsite: http://stateenergyoffice.wi.gov/Maria Redmond, Senior Analyst & Program Manager, Transportation FuelsMaria.Redmond@wisconsin.gov608-266-1521