Storage Handling and Dispensing of CNG

As per T4S guildlines-2020

© Abhishek Padiyar
What this Presentation will Cover?
This presentation will cover the minimum requirements in;

 Design
 Operation
 Inspection
 Maintenance
 Training
 consumer safety,

at Retail Outlets CNG dispensing station.

© Abhishek Padiyar
Some Important Definitions

 Cascade : Is a group of gas cylinders interconnected by high-pressure tubing

to form a single gas storage unit.

 Compressed Natural Gas (CNG) : It is the mixture of hydrocarbon gases and

vapours, consisting predominately Methane in gaseous form which has been
compressed for use as automotive fuel conforming to IS: 15958/IS:
15320:2012

© Abhishek Padiyar
Some Important Definitions
CNG Mother Station: The CNG facility connected to natural gas pipeline and
having a compressor meant primarily to fill mobile cascades and such facilities,
in addition to act as ‘mother’ station can also fill stationary cascades for CNG
dispensing into vehicles.

Source: Citygas.co.in © Abhishek Padiyar

Some Important Definitions
CNG On line Station: This means the CNG facility connected with natural gas
pipeline and having a compressor primarily to fill stationary cascades for
dispensing CNG to vehicles and in case the ‘on line’ station has enough space to
accommodate mobile cascades filling, it can be used to act as mother
compressor station.

Source: Citygas.co.in © Abhishek Padiyar

Some Important Definitions
CNG daughter station: It is the CNG facility not connected to natural gas pipeline
and dispensing CNG to the vehicles through mobile cascades.

Source: Citygas.co.in

© Abhishek Padiyar
Some Important Definitions

CNG daughter booster Station: It is the means CNG facility not connected to
natural gas pipeline and dispensing CNG to the vehicles through CNG booster
compressor and mobile cascade.

Source: Citygas.co.in
© Abhishek Padiyar
Some Important Definitions

 Vehicle Refueling Probe : A CNG refueling device fitted at the end of the
refueling hose at the dispenser units.

 Vehicle Refueling Shut Off Valve : A quick action valve for stopping gas flow
and having the facility for venting residual high-pressure gas in the refueling
line after completion of the vehicle refueling operation.

Note:The quality of Compressed Natural Gas (CNG) for automotive purposes is

governed by IS:15958.

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ODOURISATION

 Natural gas introduced into any system covered by the standard should have a
distinctive odour strong enough to detect its presence down to a
concentration (of CNG) in air not exceeding 20% of the lower limit of
flammability and to achieve such standard, the injection of odorizing agent
shall be done in a quantity to ensure perception of CNG leakage by smell as
per IS:15319.
 The odorisation pumping as well as filtration system shall have 100% stand-by
capacity.

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FACILITY PLANNING

 The CNG refueling system shall comprise of a gas compression apparatus,

static or mobile cascade or pressure vessel and a gas dispenser incorporating
a measuring device and the CNG station can also have an air compressor and
an air dryer system for actuation of valves and the system shall be `ON-LINE'
mother refueling or daughter dispensing system attached to a mobile
cascade.
 Note: - The systems and components of CNG facility(ies) shall be certified for
CNG use and marked accordingly by applicable statutory authority or the
agency authorized by such authority.

© Abhishek Padiyar
Layout and Inter distances for a CNG station
installed inside a MS or HDS service station

 Inside a MS (Motor Spirit/Petrol) or HSD (High Speed Diesel) Service Station,

the CNG storage and dispensing facilities shall be located in an isolated area
not interfering in the vehicular movement on the drive way and not coming
within the hazardous areas of petroleum facilities as prescribed in the Fourth
schedule of the Petroleum Rules, 2002 And the CNG facilities shall not be
located beneath bare electric power lines or where exposed by their failure.
 The compressor fencing may be limited to avoid obstruction in the driveway if
the required clear space is available thereafter within the service station
premises and the dispensing unit may also be located farther from the fence
enclosure on a separate pedestal observing the minimum safety clearance
mentioned in Table given in the next slide.

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 INTER DISTANCES BETWEEN VARIOUS FACILITIES OF NATURAL GAS HANDLING AT INSTALLATION

Sr. Distance from (in m)

No. Distance to
CNG Compressor CNG Storage Outer boundary MS or HSD Vent of MS or HSD Filling point of MS or
Dispenser Cascade wall or dispenser underground storage HSD
Chainlink tank
fencing
1 CNG compressor - 3m 2m 3m 6m 6m T1
(Min 3m)

2 CNG Dispensing unit 3m - 2m 4m 6m 4m T1

(Min 3m)

3 Storage Cascade 2m 2m - T1 T1 (min-6m) T1 (min-4m) T1

(Min 3m)

4 Outer Boundary or Fencing 3m 4m T1 - 6m 4m T1

(Min 3m)

5 MS or HSD dispenser 6m 6m T1 (min-6m) 6m - 6m T1

(Min 3m)
6 Vent of MS or HSD u/g 6m 4m T1 (min-4m) 4m 6m - 6m
storage tank
7 Filling Point of MS or HSD T1 T1 T1 T1 T1 6m *
(Min 3m) (Min 3m) (Min 3m) (Min 3m) (Min 3m)

© Abhishek Padiyar
NOTES:
(i) T-I denotes Table-I;
(ii) Distances shown as “–” shall be any distance necessary for operational
convenience;
(iii) A suitable curbing platform shall be provided at the base of the dispensing
unit to prevent vehicles from coming too near the unit;
(iv) A CNG cascade having cylinders of total water capacity not exceeding 4500
liters can be mounted on top of the compressor super structure. The assembly
shall observe 3-meter clearance around and also from the dispensing unit and
such distance can be reduced to 2 meter as per Note- I of Table – I; and
(v) * As per T4S regulation for “STORAGE, HANDLING AND DISPENSING AT
PETROLEUM RETAIL OUTLETS”

© Abhishek Padiyar
LAYOUT AND INTERDISTANCES
 CNG Compressors or Storage units installations shall be permitted to use alternate
equipment locations (e.g. when installed on the top of the RCC canopy) with
validation by a qualified engineer with proven expertise in mechanical systems,
structural system, electrical systems, gaseous storage systems, fire protection,
and gas detection
 If compressor is installed on the top of the canopy, installation the validation shall
be given after complying the following safety requirements:
(Note: If a compressor is installed on the top of the canopy, installation of
cascades above such compressor shall not be permitted)
a) Process safety analysis and hazard and operability studies (HAZOPS).
b) Mitigating fire protection measures such as suppression system as per NFPA-17.
Further, if compressor is mounted inside soundproof canopy or enclosure,
automatic CO2 flooding system as per NFPA-12 shall be provided.
c) Fire and gas detection systems designed to interface with an emergency shutdown
device (ESD).

© Abhishek Padiyar
LAYOUT AND INTERDISTANCES
d) The structure supporting such installations shall meet 4 Hr Fire rating in line
with IS 1642:1989-Code of practice for fire safety of buildings.
e) IS 875- Part 1 to 5 (1987): Code of Practice for Design Loads (Other than
Earthquake) for Buildings and Structures including for movable and immovable
loads, vibrations at partial or full loading conditions of the CNG compressor.
f) The structure, Foundation shall be designed for the seismic zone as per IS
1893 (Part 1) 2002 for Seismic loads;
g) Alternate Emergency escape routes shall be provided for operating crew in
case the equipment is installed at top of the canopy or elevated platform;
h) Protective hand railings shall be provided on such elevated roof top’s or
elevated platforms to prevent accidental fall of operating crew

© Abhishek Padiyar
LAYOUT AND INTERDISTANCES
i) Weather protection from sun and rain (ventilated canopy) shall be provided
for cascades.

i) Emergency shut down (ESD) system shall be provided and this device, when
activated, shall shut off the power supply to the compressor and gas supply
to the dispenser immediately;

i) An emergency manual shutdown device shall be provided within 3.0 m of the

dispensing area and also at a suitable remote manned location;

j) Control circuits shall be arranged so that, when an emergency shutdown

device is activated or electric power is cut off, systems which shut down
remain off until manually activated or reset after a safe condition is
restored; and

k) The main stairs for accessing such elevated platform shall be minimum 1.2 m
wide
© Abhishek Padiyar
Provisions related to Convenience store
or ATM or office cabin at CNG station
 The items to be sold from a Convenience Store (C-Store) in a retail outlet
shall be decided keeping in view hazards associated with the items being
stocked and sold and the open flame appliances shall not be used in the retail
outlet;
 Provision for car parking shall be made in retail outlet with C- Store @ one
slot distinctly marked for each 25 sq. meter of C-Store area;
 Separate pathways outside dispensing area shall be provided for movement of
customers for C-Store;
 The CNG dispensers shall maintain a minimum distance of 4m from any above
ground structure or property boundary; and
 Any building or room intended to serve as a control point for a retail outlet
shall preferably be so located that an attendant in the sales room can see the
forecourt and dispensing area clearly.

© Abhishek Padiyar
 INTER DISTANCES
FROM BUILDINGS AND OUTER BOUNDARIES
TO GAS STORAGE UNITS

Table 1

Sr.No. Total Capacity of Gas storage unit Minimum distance from Buildings
(in WL) and boundaries (in m)
1 Up to 4,500 WL 2.5m
2 4,500 WL to 10,000 WL 4m
3 10,000 WL to 100,000 WL 10m

© Abhishek Padiyar
Note point for the previous slide:

1) If on the side towards the boundary of the installation, the clearance as

specified in the Table is not available, the same may be reduced to 2 meters
provided a 4 H-FRR (As per IS 1642 (1989)) RCC wall of adequate height and
length covering the cylinder cascades is constructed at the boundary and
adequate clear space is available on the other side of the wall.

2) If Multiple cascades are located maintaining inter-distance of minimum 1 m,

then, the required safety distances shall be considered as applicable in case
of the water capacity of the higher capacity individual cascade.

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Stationary cascade
 The cascade having horizontal cylinders and sited parallel to other cascade or
cylinder fittings should be arranged so that they do not face cylinder fittings
of other cascade.

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Stationary cascade
 Cylinder installed horizontally in a cascade shall be separated from another
cylinder in the cascade by a distance of minimum 20mm.
 Cascade with horizontal cylinders shall have the valves fitted on the same
side within the cascade opposite to the refueling point and arranged in a
manner that any gas leakage is discharged upwards.
 Cascade shall be securely anchored to prevent floating in case flooding is
anticipated.
 Gas storage facility shall be protected from the effects of the weather by a
roof or canopy designed to facilitate the dispersion of free or escaped gas.
 Cascade storage on the top of the roof shall be permitted on first floor and
there shall not be any further construction or inhabitation above this storage.

© Abhishek Padiyar
Stationary cascade
 The frame structural members must be designed for a vertical load of 2 times
the maximum gross weight of the bundle and the design stress levels shall not
exceed is as per IS 800.
 The frame design must prevent collection of water or other debris that would
increase the tare weight of bundles filled by weight.
 The cylinders shall be manufactured as per IS 7285-1, IS 7285-2, ISO 11119-1,
ISO 11119-2, ISO 11119-3, ISO 11120, EN 12245, EN 12247.
 Individual cascade shall have all cylinders of a particular make, type and
capacity and all cylinders in a cascade shall conform to a single design code.

© Abhishek Padiyar
Mobile Cascade
 Only dedicated trailer, truck or any other vehicle to be used for
transportation of CNG storage units and such units should have lugs fitted for
lifting and in no case magnetic device to be used for lifting purposes.
 The vehicle with the cascade thereon, shall be placed with easy access and
egress on a low platform or hard compacted ground, which shall extend to at
least another one meter on all sides and this platform or hard ground shall be
under a light roof or canopy.
 The trailers or vehicle carrying CNG should be made immovable by application
of brake and wheel choke prior to initiation of filling or dispensing operation.

© Abhishek Padiyar
Mobile Cascade
 Whether attached to a trailer or mounted on a vehicle chassis frame the cascade
shall be designed to meet the following; namely
1) The cylinders in a cascade must be structurally supported and held together as a
unit and secured in a manner that prevents movement in relation to the structural
assembly and movement that would result in the concentration of harmful local
stresses and the frame design must ensure stability under normal operating
conditions.
2) The frame must securely retain all the components of the bundle and must protect
them from damage during conditions normally incident to transportation and the
method of cylinder restraint must prevent any vertical or horizontal movement or
rotation of the cylinder that could cause undue strain on the manifold or cylinder
shell and the total assembly must be able to withstand rough handling, including
being dropped or overturned. (Refer CGA TB 25 Design Considerations for Tube
Trailers or Tube Modules);

© Abhishek Padiyar
Mobile Cascade
3) The frame must include features designed for the handling and transportation
of the bundle;
4) The frame structural members must be designed for a vertical load of 2 times
the maximum gross weight of the bundle and the design stress levels shall not
exceed is as per IS 800;
5) The frame must not contain any protrusions from the exterior frame structure
that could cause a hazardous condition;
6) The frame design must prevent collection of water or other debris that would
increase the tare weight of bundles filled by weight;
7) The floor of the bundle frame must not buckle during normal operating
conditions

© Abhishek Padiyar
Mobile Cascade
8) Each new Cascade design beyond 4500 lt water capacity must have a design
approval certificate and the manufacturer shall obtain approval of a new
design along with the copies of all engineering drawings, calculations, and
test data necessary to ensure that the design meets the relevant specification
from a firm of repute e.g. FM/UL;
9) Individual cascade shall have all cylinders of a particular make, type and
capacity and all cylinders in a cascade shall conform to a single design code.
10) Seamless cylinders longer than 2 m (6.5 feet) shall be mounted horizontally
for transportation on a motor vehicle or in an ISO framework or other
framework of equivalent structural integrity in accordance with CGA TB–25;

© Abhishek Padiyar
Mobile Cascade
11) For the dimensions of ISO framework for transportation, the ISO 6346 shall be
referred;
12) Arrangement for static electricity discharge from LCV shall be made during
loading and unloading of CNG from the cascade on the vehicle; and
13) Mobile cascade vehicles running on HSD shall be fitted with spark arrestors
and the spark arrestors shall be valid and of mark approved by PESO.

© Abhishek Padiyar
Compressor Station
 The piping and its fittings up to the battery limit of CNG installation shall
conform to ASME B 31.8 or equivalent.
 Compressor shall be designed for use in CNG service and for the pressures and
temperature to which it may be subjected under normal operating conditions
conforming to API 618/ API 813 / API 11 P or equivalent standard and flame
proof electric motor and associated fittings should conform to IS/IEC 60079
suitable for Gas Group IIA as applicable for Natural Gas.
 Compressor shall be fitted with the following minimum devices; namely: -
1) Pressure relief valves on inlet and all stages to prevent pressure build up
above the predetermined set point;
2) High discharge temperature shut down;

© Abhishek Padiyar
Compressor Station
3) High cooling water temperature switch fitted to cooling water return line to
shut the compressor in the event of a fault;
4) High, inlet, inter stage and discharge pressures shut down;
5) Low lube oil pressure shut down;
6) Low cooling water flow switch fitted to the cooling water return line to shut
the compressor in the event of fault; and
7) A remote isolation switch for emergency shut down to be provided with
manual reset at control panel.

© Abhishek Padiyar
Compressor Station
 Compressor shall be provided at least the following clear and permanent markings
readily accessible and easy to read in the installed position; namely: -
a) Manufacturer's name;
b) Model;
c) Serial No. or month and year of manufacture
d) Certificate of approval no.;
e) Rated capacity (cubic meter per hour);
f) Operating speed (RPM);
g) Required driving power (in kW);
h) Maximum and minimum supply pressures;
i) Maximum outlet pressure; and
j) Certification for Natural Gas use.

© Abhishek Padiyar
Dispensing unit
 Dispensers shall be installed on a suitable foundation observing the minimum
safety distances and like other precautions. as given in Table (in slide 12) and
the dispensing unit to be protected against possible damage by vehicular
movement and the dispenser mounting and installation shall be in accordance
with NFPA 52 and NFPA30A or as per design standard.
 The flexible hoses fitted on the dispenser shall be mechanically and
electrically continuous and the design, material and construction of hoses
shall be suitable for CNG and shall withstand not less than 4times the
maximum working pressure of the system.
 The dispensing unit shall be of a type approved by the Petroleum and
Explosives Safety Organisation or concerned Statutory Authorities.
 Dispensing unit shall be suitable for use of CNG in accordance with NGV
(Natural Gas Vehicle) 4.1 and hoses as per NGV 4.2 and breakaway as per NGV
4.4.

© Abhishek Padiyar
 Cylinders
 The cylinders and their fittings for CNG use shall be designed, manufactured,
tested including hydrostatic stretch test at a pressure in full conformity to IS
7285-1, IS 7285-2, ISO 11119-1, ISO 11119-2, ISO 11119-3, ISO 11120, EN
12245, EN 12247 or other national or international standards having approval
from statutory authority under Gas Cylinder Rules, 2004 i.e. Petroleum and
Explosives Safety Organization considering the maximum allowable operating
pressure of 250 bar.
 These cylinders are to be permanently and clearly marked for “CNG only” and
also labelled "CNG ONLY" in letter at least 25 mm high in contrasting colour in
a location which shall be visible after installation.
 The cylinder shall be fabricated from steel or composite materials as per the
national or international design codes mentioned above or any other standard
duly approved by the Petroleum and Explosives Safety Organization.

© Abhishek Padiyar
Cylinders
 The cylinders shall be re-examined or re-tested every three years and in
accordance with Gas Cylinder Rules, 2004 by a competent person in line with
the directives of the Petroleum and Explosives Safety Organisation with due
markings and no cylinder shall be used which has not been duly re-tested as
specified in.
 Cylinders shall be painted white to reduce solar heating effect and protect it
from atmospheric corrosion.

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CNG Tubing
 All rigid piping, tubing, fittings and other piping components shall conform to
the recommendations of ANSI B 31.3 and all the elements of piping should be
designed for the full range of pressures, temperatures and loading to which
they may be subjected with a factor of safety of at least 4 based on the
minimum specified tensile strength at 20 deg. C.
 Gaskets, packing and any other materials used shall be compatible with
natural gas and its service conditions.
 All the piping and tubing shall have minimum turns with adequate provision
for expansion, contraction, jarring, vibration and settling and the exterior
piping may be either buried with suitable corrosion protection or installed 30
cm. above the ground level with supports and protection against mechanical
and corrosive damage.

© Abhishek Padiyar
CNG Tubing
 Rigid pipelines shall have welded joints between their respective
components.
 All the piping and tubing shall withstand a pressure equal to that of safety
relief device and tested accordingly after assembly and the testing to be done
by inert gas and in case natural gas is used the suitable safety measures to be
adhered to.
 The fuel lines shall have a positive segregation with electrical cables.

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Valves
 A minimum of 4 shut off valves shall be fitted between the gas storage unit
(Cascade) and vehicle refueling filling nozzle as explained below, namely: -
a) Each CNG storage unit to have quick action isolation valve in the steel supply
pipe immediately adjacent to such storage unit to enable isolation of individual
storage unit and such valves shall be within fencing of storage unit (applicable
in case of mother/online station).
b) Master shut off valve with locking arrangement in close position, shall be
installed in steel outlet pipe outside but immediately adjacent to the gas
storage unit to isolate all downstream equipment from the gas storage unit and
such valve shall be outside the fencing (applicable in case of mother/online
station).

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Valves
c) A quick action emergency and isolation shut off valve shall be installed near
dispensing unit with easy approach and to remain closed when refueling is not
being done; and

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Valves
d) A vehicle refueling shut off valve shall be installed for each flexible vehicle
refueling hose to control the refueling operation and shall have venting
provision to allow for the bleeding of the residual high-pressure gas after
refueling is complete.

 All these valves like other markings shall have permanent marking for service
rating.
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CNG Hoses
 Internally braided, electrically continuous, non-metallic and metallic hoses
resistant to corrosion and suitable to the natural gas service shall be used for CNG
service in the downstream of emergency and isolation shut off valve.
 The flexible hoses and their connections shall be suitable for most severe pressure
and temperature service condition expected with a burst pressure of at least
4times the maximum working pressure.
 The flexible hoses with their connections shall be tested after assembly and prior
to use to at least 2times the working pressure and also tested to a pneumatic
pressure of at least 400 bar under water and thereafter, all the hoses shall be
examined visually and tested for leaks with soap solution at an interval not
exceeding 1 year and hoses shall be rejected and destroyed in the event of any
leakage and such tests are to be recorded and such records shall be available at
installations at all times and such tests, examinations, rejections and destruction
shall be done safely in a controlled environment by the trained technicians having
adequate expertise with respect to the assembly of hoses, breakaways, valves and
fuel nozzles.

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CNG Hoses
 Flexible hoses shall have permanent marking indicating the manufacturer's
name or identification, working pressure and suitability for use with CNG.
 CNG flexible electrically conductive hose shall be meeting the requirement as
per NFPA-52 or NGV 4.2 or equivalent.

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Pressure Gauges
 Every CNG storage unit including each cascade or bulk storage tank shall be
provided with a suitable pressure gauge directly in communication with them.
 The CNG storage unit shall have an opening not to exceed 1.4-mm diameter
at the connection where pressure gauge is mounted.
 The pressure gauge shall have dial graduated to read approximately double
the operating pressure but in no case less than 1.2 times the pressure at
which pressure relief valve is set to function.
 All pressure gauges in the installation shall be tested and calibrated at least
once a year and records maintained.

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Pressure Relief Device
 Safety Relief Devices may consist of either burst disc or safety relief valve and
should conform to the requirements of API 520 or equivalent equipment
design standards.
 Safety relief devices shall be installed with unobstructed full size discharge to
a safe place on bulk tanks and cylinders in the vertical position with suitable
rain caps and such devices should have their outlet arranged in a manner so
that in case of emergency a high-pressure gas escapes from the devices
should not directly hit on operators or persons in the close vicinity.
 Cylinder should have safety relief devices fitted in conformity to the Gas
Cylinder Rules; 2004.

Safety relief valve

(Cascade)

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Pressure Relief Device
 Piping shall be protected by safety relief devices in conformity to design
standards.
 Safety relief valves shall have a locking arrangement to prevent tampering by un
authorized persons and any adjustments to the safety relief valves shall be made
by manufacturer or a competent person and such valves should have a permanent
tag indicating pressure setting, date of re-setting or setting and capacity.
 All safety relief devices shall be tested at least once a year for proper operations
and records to be maintained.
 All the safety relief devices shall have manufacturer's permanent marking
indicating the following; namely: -
a) Set pressure to start discharge; and
b) Discharge capacity in Cum/min.

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Pressure Relief Device
 No shut off valves shall be installed between the safety relief device and the
gas storage unit or bulk tank.
 All natural gas devices not otherwise specifically mentioned shall be
constructed and installed to provide a safety equivalent to that other parts of
the system.
 Gas detectors interlocked with compressor cut out switch in the electrical
system of the compressor are to be installed which would automatically
switch off the unit in case of major gas leak.

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Electrical Equipment
 All electrical wiring and equipment, gas storage dispensing unit located in
hazardous area Division I and II shall be in accordance with the law in force
relating to electricity, Gas Cylinder Rules,2004 and IS:5571, IS:5572, NFPA - 52.
 The earthing at the installation, protection against ignition arising out of static,
lightning and stray currents shall be the law in force relating to electricity.
 The following elements and components shall be considered in designing the
electrical power distribution system; namely: -
i. Total electrical load for the entire Retail Outlet;
ii. Availability, Suitability and Reliability of the State Electricity Board (SEB) grid;
iii. Fault (KA) rating of the SEB Feeder;

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Electrical Equipment
iv. Load to be fed from back-up;
v. Load which need stabilized or Uninterrupted Power Supply (UPS) supply, or
both to function smoothly; and
vi. Rated load of the connected and future equipment.
For downstream distribution on the LT side, a suitable LT power distribution
panel (PDP) shall be designed, to feed the various types of loads safely, from a
centralized location.

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Electrical Equipment

 Elements of Protection
Elements of Protection:
a) Protection shall be provided to guard against sudden failures viz.
disconnection of “Neutral” and against overload, short-circuit and earth fault;
b) The motors shall be protected against short circuit and overload; and
c) Protection shall be provided for variation in voltage, frequency and phase
imbalance.

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Electrical Equipment

 Backup Power Supply:

The following shall be considered to arrive at the capacity of the Diesel
Generator (DG) set or Renewable Energy system and like other set or system, if
provided; namely: -
i. “Critical” lighting fixtures; and
ii. The Backup rating shall be sufficient enough, to sustain the starting power
requirements, of the connected motors, without disturbing normal operation
of the other loads.
When operating before sunrise or after sunset, emergency lighting shall be
provided for safe operation of power backup equipment.

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Electrical Equipment
 Layout and Installation
i. For HT supply, the substation shall mainly consist of lightning arrestor, HT fuse,
transformer and SEB metering cubicle and for retail outlets with an outdoor type
of HT or LT substation, a DP structure surrounded with barbed wire fence, entry
gate shall be provided and alternatively, a packaged sub-station shall be provided.
ii. The power distribution panel, automatic voltage stabiliser and UPS shall be
installed with following clear spaces for ease of safe operation and maintenance
activities:
in front of the equipment - 1000 mm.
behind the equipment - - > 750 mm. (if approach is required)
- < 200 mm (if approach is not required)
at sides - > 750 mm. Between equipments
- < 200 mm. (if approach is not required);

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Electrical Equipment
 Electrical room shall be provided with proper ventilation to extract the heat
generated in the power distribution equipments;
 All electrical equipment shall be as per IS: 5571 in line with hazardous area
classification and the zone classification has been depicted in Annexure-I;
 Cable entry shall be through gland plate either at top or bottom and further
spare holes, if any, in the gland plates shall be blocked;
 Cables shall be neatly dressed, clamped and tag marked to easily identify the
feeder and device it connects;
 The cable entry holes on the building wall in cable trench or overhead shall
be sealed to prevent entry of water.

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Electrical Equipment
 For underground laying under different conditions of terrain the methods may
be as follows; namely: -
a) For direct burial within RO (Retail Outlet), top of the topmost layer of cable
shall be laid at a minimum depth of 600 mm from surface of ground and each
subsequent layer at the bottom shall maintain a minimum vertical clearance
of 150 mm; and
b) For road crossings, cables shall be routed at a minimum depth of 600mm from
surface and through pipe and the pipe may be of GI or steel reinforced hume
pipe or HDPE pipe.

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Electrical Equipment
 Earthing System:
a) The earthing system shall be designed as per IS 3043 and following procedures
shall be followed; namely: -
b) All metallic structure, pipe fittings and enclosures of electrical equipments
shall be connected to earth.
c) For Equipment rated up to 230 V, 1-phase supply, the enclosure shall be
grounded at least at one point.
d) And for Equipment rated above 400 V, 3-phase supply, the enclosure shall be
grounded at least at two separate points.
e) Two nos. earth pits shall be provided for each of transformer or DG set
neutral earthing / equipment earthing.

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Electrical Equipment

f) All earthing pits except DG neutral, structure, T/T (Tanker/Cylinder Truck)

Unloading point and instrument or IT earthing shall be connected through grid
or grids; and
g) In areas prone to lightning, a risk assessment shall be carried out for need of
lightning protection and guidelines given in IS 2309 shall be followed.

© Abhishek Padiyar
Electrical Equipment
 Emergency Stop System :
i. Emergency stop system shall be provided to cut off the power supply to all
metering pumps or dispensing equipment and associated equipment, other
than certified intrinsically safe equipment at PDP (Power Distribution Panel),
and in or on sales building and on actuating any of these push buttons,
electrical power supply to entire RO, except yard lights, shall be isolated
instantaneously; and
ii. The push button shall be of red colour, mushroom type, marked and with a
key to open.

© Abhishek Padiyar
Electrical Equipment
 Illumination System: Following minimum illumination level (Lux) shall be
maintained in various areas of the RO (for safety and visibility; namely: -

Area LUX
Approach area 50
Under the canopy 150
Customer care room 100
Electrical room or compressor area 100

The design shall ensure that illumination is glare-free for customers driving in.

© Abhishek Padiyar
 Safety at Vehicle for refueling
 The vehicles shall have approved type of CNG kit fitted in accordance with
the guidelines of Government of India, Ministry of Surface Transport, and
authorised in a workshop conducted for such purpose and such workshop
should issue a fitness certificate to the vehicle for its suitability for CNG use
and such certificate should be always carried by the driver of the vehicle at
all times.
 Driver of the vehicle should also carry the record showing the last
examination of the vital parts of the system fitted in the vehicle for CNG use
and their next due date for such examination and such record must include
the test periodicity of cylinder, pressure relief devices, pressure gauges,
piping and other like requirements.
 The cylinder with valves and connected facilities fitted in the vehicle shall be
in accordance with Gas Cylinder Rules,2004 and such cylinder should be
subjected to hydraulic test at least once every three years.

© Abhishek Padiyar
Safety at Vehicle for refueling
 Every vehicle using CNG fuel system should display “CNG” labels prominently
in compliance to the law in force relating to motor vehicle.
 Manufacturing of Type-1 and Type 2 Nozzles shall be in accordance with NGV1
and ISO 14469-2 standards.

© Abhishek Padiyar
CNG Refueling into vehicles
 The vehicle refueling shall be done by an experienced operator duly certified by
the oil or gas company having control over the refueling station.
 The operator of the CNG dispensing unit shall check the following prior to
refueling the gas, namely: -
a) The driver of the vehicle is carrying updated history record as specified in the
previous slide ;
b) There is no smoking, naked flame or any other source of ignition within six meters
of the refueling point’;
c) There is no leakage in the CNG fuel system reported by the driver of the vehicle;
d) The fuel connection is in good condition and matches the dispensers filling nozzle
and the fuel connection shall be tight without any leakage;
e) The engine is switched off, hand brake is firmly applied, the vehicle parked in
gear or in "P" with automatic transmission; and
f) No passenger including crew remain inside the vehicle.

© Abhishek Padiyar
CNG Refueling into vehicles
 Detailed precautions (as specified in slide no. 62) and the procedure of
refueling to be displayed near the dispensing unit and the same shall be
strictly followed by the operator.
 The operator of the dispensing machine should not leave the vehicle being
refueled.
 The cylinder on the vehicle shall not be charged in excess of maximum
allowable working pressure at normal temperature for the cylinder.
 Before the refueled vehicle is driven away from the dispensing point the
operator and driver should ensure that there are no apparent gas leaks either
on the vehicle or on the dispensing point that may have been caused through
faulty filling or the faulty action of connecting or disconnecting.

© Abhishek Padiyar
CNG Refueling into vehicles
 Warning signs depicting "STOP VEHICLE", "NO SMOKING", "NO OPEN FLAME
PERMITTED", “FLAMMABLE GAS", “NO MOBILE PHONE”, “SWITCH OFF THE
MOBILE PHONES” shall be displayed on suitable places at the dispensing
station and compressor areas and the location of the signs shall be such that
they are prominently visible from each point of the transfer or operation.
 The operator shall take all measures for ensuring smooth vehicle movement in
the outlet including restriction on number of vehicles near the fill points.

© Abhishek Padiyar
Fire Protection
 Fire fighting facilities need to be carefully planned after considering the
availability of municipal fire tenders and other related matters and, at least
the following portable fire extinguishers shall be positioned, namely: -

Sr. No. Location Type of Extinguishers

1 Dispensing Unit 1* 9kg DCP/ ABC with dial gauge
2 Compressor (on-line) 1* 9kg DCP/ ABC with dial gauge
3 Mother Station 1* 75kg DCP
4 CNG Storage 1* 9kg DCP/ ABC with dial gauge
5 Cascade refueling area 1* 9kg DCP/ ABC with dial gauge
6 MCC or Electrical installation 1* 4.5kg CO2 per 25 Sq.m. floor area.

© Abhishek Padiyar
Fire Protection
 Any other flammable materials not specified in this standard in the CNG
installation shall be stored in a non-flammable chamber with a minimum
safety distance of 15 M from compressor station or MCC or electrical
installation, as the case maybe.
 All approaches to machines, compressors, storage facilities and work places
shall be free from obstacles, so that they are readily accessible in an
emergency.
 The electrical installations shall be inspected by an Electrical Inspector as per
IE Rules in force and compliance shall be made as pointed out in the
inspection and the records shall be maintained for all periodic inspections.
 The flameproof characteristics of electrical equipment shall be checked
through visual checks, condition of gasket, completeness and tightness of
bolts, glands and as recommended by manufacturer's test certificates.

© Abhishek Padiyar
Fire Protection
 The unauthorized additions or modifications of the service station whether
temporary or permanent, which are nor permissible or authorized under the
law or the standards in practice, shall be taken up.
 Proper illumination to be ensured for all operating and non-operating areas.
 All electrical maintenance at the Automotive Station shall be undertaken by
electrical technician licensed under law in force and under the supervision of
authorized person in this behalf.
 Each installation shall have minimum two numbers hand held explosive meter
in working conditions at all times.
 The work permit shall be issued by designated person and be followed.

© Abhishek Padiyar
Emergency Plan and Procedure
 A comprehensive ERDMP shall be developed in accordance to the Petroleum and
Natural Gas Regulatory Board (Codes of Practices for Emergency Response and
Disaster Management Plan (ERDMP)) Regulations, 2010 and copies of the ERDMP
shall be available to all personnel at the CNG dispensing station.
 The entity having control over the refueling station shall draw an operational
emergency plan in consultation with adjoining establishments and local authorities
e.g. fire brigade, police, and other District Emergency Authorities and like other
Authorities. for the following circumstances, namely: -
i. Loss of or interruption to the gas supplies due to leaks or failure of pipeline;
ii. Over-odorisation of the gas;
iii. Major failure of CNG fittings;
iv. Accidents or other emergencies, which can affect the CNG refueling, station;
v. Civil emergencies;
vi. Emergency situations during transportation of CNG through mobile cascade
vehicles; and
vii. Any other risk arising from the existence or use of the CNG refueling station.

© Abhishek Padiyar
Emergency Plan and Procedure

 The emergency plan specified in the previous slide shall be disseminated

amongst all personnel involved to ensure that they understand their roles and
responsibilities in the event of an emergency.
 The operator of the refueling station should have close liaison with Fire
Service, the Police, the Municipal Authorities and the person supplying gas to
CNG facility.
 Important telephone numbers for emergency use shall be displayed
prominently.
 Means of communication shall be always at the disposal of the In charge of
the installation on 24 hours basis.
 The emergency plan should be tested with drill at least once a year.

© Abhishek Padiyar
Competence Assurance and Assessment
 The objective is to provide good understanding of all the facets of dispensing
activities including operations, procedures, maintenance and hazards of CNG
and the risks associated with handling of the product and the training shall
ensure that the jobs are performed in accordance with the laid down
procedures and practices.
 Every entity shall develop, implement, and maintain a written training plan
to instruct all CNG dispensing station personnel with respect to the matters
specified in the below points.
I. Carrying out the emergency procedures that relate to their duties at the CNG
dispensing station as set out in the procedure manual and providing first aid.

© Abhishek Padiyar
Competence Assurance and Assessment
 Permanent maintenance, operating, and supervisory personnel with respect
to the following, namely: -
a) The basic operations carried out at the CNG dispensing station;
b) The characteristics and potential hazards of CNG dispensing station and other
hazardous fluids involved in operating and maintaining the CNG dispensing
station, including the serious danger from frostbite (an injury caused by
freezing of the skin and underlying tissues) that can result upon contact
with POL (Petroleum Oil Lubricants) products and CNG;
c) The methods of carrying out their duties of maintaining and operating as set
out in the manual of operating, maintenance and transfer procedures.

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Competence Assurance and Assessment
d) Fire prevention, including familiarization with the fire control plan of the
CNG dispensing station; fire fighting; the potential causes of fire or accident
in CNG dispensing station; the types, sizes, and likely consequences of a fire
or accident at a CNG dispensing station; and
e) Recognizing situations when it is necessary for the person to obtain assistance
in order to maintain the security of the CNG dispensing station.

© Abhishek Padiyar
Competence Assurance and Assessment
 Training shall be imparted to the staff attached with the CNG dispensing
station at the time of induction, which is to be followed up by periodic
refresher courses once every year and the training programme shall inter alia
cover the following aspects, namely: -
I. Hazardous characteristics of CNG;
II. Familiarization with operational procedures and practices;
III. Commissioning of new facilities and equipment;
IV. Hands on experience on operation of equipment;
V. Routine maintenance activities of the facilities;
VI. Knowledge of emergency and manual shut down systems;
VII. Immediate and effective isolation of any CNG leak;
VIII. Accounting of product;

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Competence Assurance and Assessment
ix. Safety regulations and accident prevention;
x. Fire fighting facilities, methods of fire fighting and its upkeep;
xi. Evacuation and safe egress of the vehicles;
xii. Housekeeping;
xiii. Safety in transportation of CNG;
xiv. First aid;
xv. Emergency plan or drills;
xvi. Natural gas leakage possibility and its containment;

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Competence Assurance and Assessment

xvii. Filling nozzles, types of gasket or seal and like device for joining; and
xviii. Access control of vehicles so as to allow the vehicle with tested cylinders to
be filled with CNG.

© Abhishek Padiyar
Competence Assurance and Assessment

 Appropriate training techniques shall be adopted which will include the

following, namely: -
a) Classroom training;
b) Hands on or practical training;
c) Demonstration;
d) Case studies; and
e) Training aids.
Proper records for the training and refresher courses shall be maintained at the
installation.

© Abhishek Padiyar
Automation
Components of Forecourt Automation:
Retail automation (Forecourt control) where provided, shall have following major
components and these components are integrated together using different
communication methods; namely: -
i. Forecourt controller (FCC);
ii. Back office system;
iii. Local area network (LAN);
iv. Wi-Fi access points;
v. VSAT or GPRS or broadband routers cum modem;
vi. Automatic tank gauging system (ATG);
vii. Electronic price signs (EPS);
viii. Payment terminals;

© Abhishek Padiyar
Automation
ix. Thermal receipt printers;
x. Attendant tag readers; and
xi. Close Circuit surveillance systems (CCTV)

These components shall be evaluated for necessary approvals based on their

location of installation in conjunction with the zone classification guidelines for
retail outlets and accordingly each of these components is described briefly in
Annexure II of T4S for “STORAGE, HANDLING AND DISPENSING AT PETROLEUM
RETAIL OUTLETS”.

© Abhishek Padiyar
Automation
Installation of Automation Components :
i. The components installed in Zone-0 and Zone-1 shall be certified for use by
competent certifying agencies;
ii. The integrity of the dispenser shall remain intact, while adding additional
cables for communication, as well as power supply to OPT or printer and
similar devices;
iii. The installation of auto tank gauging equipment probe, shall be carried out in
compliance to relevant standards, using safe arrangement for joining of the
cable at the tank manhole area;
iv. The height of pedestals used for installing, printers, outdoor payment
terminals and similar equipments shall not be less than 1.2m from the base
frame of the dispensing unit; and
v. The integration of automation components and its installation shall be done
under the supervision of qualified and trained personnel.

© Abhishek Padiyar
Safety Inspection or Audit

 The safety inspections or audit of CNG dispensing station shall be carried out
as given below, namely: -

Type Frequency Agency

General Inspection Daily Operating Personnel
General Inspection Twice in a quarter Authorized person of
marketing company
Safety Audit Once in a year Authorized person
Electrical Audit Once in 3 year Licensed Electrical
Agency

© Abhishek Padiyar