Installation Guidance : LPG (Autogas) Refueling Stations

Gas Technology Institute

March 2014

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Objectives

A. LPG Fuel

B. Fueling Basics

C. Codes and Standards

D. Station Basics

E. Equipment Location

F. Electrical Hazardous Area Classification

G. Station Installation

H. Fire Protection

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LPG Fuel

o LPG or Propane has the chemical formula C3H8

o Propane is produced when natural gas is processed and crude oil is refined.

o It is nontoxic, colorless, and odorless (odorant is typically added for detection)

o At atmospheric pressure and ambient temperatures Propane exists in a vapor form

o Like gasoline or diesel, Propane gas is heavier than air

o Propane is a NFPA Class IA flammable liquid

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Fueling Basics

oThe service pressure of a propane fuel system is at least 240 psig. At this pressure the LPG will stay a liquid at temperatures of 120° F or less

o By code, LPG fuel tanks are only allowed to be filled to roughly 80% of volume

o Fueling is either stopped by a auto stop fill valve installed in the fuel system or manually stopped by operator by observing level gauge and bleed valve vent

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Codes and Standards

Accepted Codes:

oNFPA 58: Liquefied Petroleum Gas Code 2011

oNFPA 70: National Electric Code (NEC) 2011: Article 500: Hazardous (Classified) Locations, Article 501: Class 1 Div.1 & 2 Hazardous Locations

oNFPA 30A: Code for Motor Fuel Dispensing Facilities and Repair Garages 2012 (Addresses additional requirements when LPG fueling is added to an existing liquid petroleum fuel station)

oInternational Fire Code (IFC): Chap 22 is not recognized in Wisconsin

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Station Basics

o ASME Storage Tank: Rated Design Pressures per NFPA 58: 5.2.4.2

o Pump, Metering Devices, and Dispensers (Listed): Rated for Hazardous Locations

o Card Reader System or Fuel Management System to authorize transactions

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Station Basics

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Station Basics

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Equipment Location

NFPA 58 Chapter 6 & NFPA 30A Chapter 12 address

equipment placement and set backs

o Pumps, Storage, and Dispensing Equipment are addressed

o Location, either indoors (NFPA 58 Chap10 applies) and

outdoors, of the equipment matters

o In some instances a combination of both codes will give

guides on final equipment placement e.g. tank separation

(from other aboveground fuel tanks & dispenser)

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Equipment Location

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Electrical Hazardous Area Location

NFPA 58 & NFPA 30A establish electrical area

classification for outdoor stationary Propane fueling

stations

oPressure Relief Points, aboveground storage tanks,

remote mounted pumps, dispensers, and points of

transfer are discussed in Chapter 6 of NFPA 58

Electrical Conduits and Wiring must be installed per

approved methods indicated in NEC for classified areas

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Electrical Hazardous Area Location

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Station Installation - Aboveground Tanks

o Aboveground horizontal ASME tanks are supported by

structural steel saddles and slotted and designed to allow

for expansion and contraction

o Horizontal ASME tanks are required to be installed on

masonry or other noncombustible supports located on

concrete or masonry foundations

o For containers 2000 gal. or less the pump can be

mounted on a common base assuming bottom of

container meets dimensions

o Tanks are to be physically protected

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Station Installation - Piping

o Piping sizes range from ¾” to 2” depending on

dispenser design

oMetallic piping and fittings are to be fabricated,

installed, and tested per ASME B31.3, Process

Piping Code

o Pressure Ratings defined in NFPA 58: 6.9.3.3

oMetallic pipe joints are permitted to be threaded,

flanged, welded, or brazed

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Station Installation - Piping

oPiping systems should be routed in a practical

manner from point to point

oMinimum cover depth is 12”, this is increased to

18” if there is potential for external damage

oBuried metal pipe must be protected against

corrosion

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Station Installation - Dispenser

oThe dispenser should be a listed device NFPA

30A: 6.3.2

oDispenser installed under a canopy, the area shall

be ventilated and have at least 50% of perimeter

open to outdoors

oProtection against trespassing and tampering

should be installed

oDispenser should be installed on a concrete

foundation or apart of a complete storage and

dispensing unit mounted on the same base

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Station Installation- Dispenser Cont.

oHose length is not to exceed 18 ft., listed, and

protected from damage if not used

o Listed breakaway device per ANSI/UL 567

o Identified and accessible switch or circuit breaker

should be installed within 20 -100 ft. of dispenser.

Markings for the switch should be made visible at

point of transfer

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Station Installation- Misc.

o An excess flow valve or differential back pressure valve

should be installed where LPG hose is connected to liquid

piping

o Hydrostatic relief valves installed between isolating shutoff

valves

o The LPG tank opening should be equipped with either 1)

internal valve fitted for remote closure and automatic shutoff

using thermal actuation or 2) a positive shutoff valve located

as close to the tank as possible in conjunction with an

excess flow valve and a remotely actuated emergency

shutoff valve

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Station Installation- Misc.

o An emergency shutoff device (switch, button, lever, etc.)

shall be required within 3 -100 ft. from the liquid transfer

point

o Actuated emergency shutoff and internal valves should be

tested annually

o Manual shutoff valve and excess flow valve shall be

located in liquid line between pump and dispenser when

dispenser is remote to pump/storage location

oTypically safety devices/features are included in the

equipment and/or station design

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Station Installation- Shutdown and Safety Device Schematic

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Fire Protection

o Fire Protection is required for installations with an

aggregate water capacity greater than 4000 gal.

o If required, a Fire Safety Analysis shall be submitted to the

AHJ by owner operator of the station.

o NFPA publishes the “Fire Safety Analysis Manual for LP-

Gas Storage Facilities” providing guidance in completing

an analysis in conjunction with NFPA 58 requirements.

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References

o AFDC’s Propane Fuels and Vehicles sections (www.afdc.

energy.gov)

o Local Clean Cities coordinator (www.cleancities.energy.

gov)

o Propane Education & Research Council

(www.autogasusa.org ; www.propanecouncil.org)

o National Propane Gas Association (www.npga.org)

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Acknowledgement of Support

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Questions?

Thank you for your time.

J. Sells – Director Autogas – 904-545-9743 j.sells@amerigas.com

David Rigney – National Account Manager (West-South) – 386-299-9442

david.rigney@amerigas.com

Chris Ransom – National Account Manager (East-Central) – 231-638-3184 chris.ransom@amerigas.com

Autogas 101

Propane Autogas • Clean burning

• Readily available

• Most widely used alternative motor fuel in the world

• 3rd most commonly used motor fuel

• Powers approx 270,000 vehicles in the US

• Only alternative fuel with existing fueling stations in every

state

DOMESTICALLY PRODUCED

Around 97% of propane

autogas is produced here in

the U.S., reducing our

dependence on foreign oil and

increasing American energy

security.

Propane Autogas Pricing

• Relative to Gasoline/Diesel

• 9/24/2013 – LPG $1.89, Gasoline Reg. unleaded $3.59,

Diesel $4.10

• Relative to Propane for home, commercial, cylinder gas

applications

• –Priced differently

• –Awareness of retailer pricing propane as autogas vs.

cylinder gas

• Winter Spike – supply and demand

• Limited # of distributors in market

• Propane Autogas priced with excise taxes

• Currently $.50 per gallon tax credit

Propane Autogas Refueling Infrastructure

Fleet Users

•Autogas station installed on-site at fleet base

•Spill-free dispenser with familiar design

•Fully scalable to serve fleets of all sizes

•Works well with fuel management systems

•All necessary training for fleet personnel

•Installation time –as fast as 1-2 days

Example:

1,000 gallon tank/pump/meter/hose/nozzle/cabinet

30,000 gallon tank, pump, dispenser, systems integration

Infrastructure installation requires fuel consumption

(difficult to consider installing infrastructure for a fleet with

only a few vehicles)

Electronic Autogas Refueling Station

Infrastructure Cost Factors

• Tank and support costs

• Lines and installation

• Pump

• Dispensing mechanism

o Basic electronic to full service including software

integration, card readers, fuel management, printers,

etc.

• Electrical Supply –single phase or three phase current

• Impact Protection

• Cost of autogas refueling infrastructure is significantly

lower than other alternatives

• Mobile – easily relocated

• Refueling stations may be installed at no cost in exchange

for a fuel contract

Support/ Maintenance

• Provide regular interval training and system

inspections

• Minimal Response Time

• Alternative Fueling Options

–Mobile Refueling

–Retailers

–Dual Fuel Systems

• Minimal to zero lost time

Vehicle Conversions

• Bi-Fuel Conversions systems –EPA Emissions Certifications – time/cost

–Cost effective – rapid ROI for certain vehicles

($5500-$7200)

–Operating Range significantly increased

–Transferable to other certified engines

–Warranty

–Technology advancements vs. consumer

beliefs

Vehicle Conversions

OEM/Dedicated

–EPA Emissions Certifications

–Cost difference – ($10,000-$12,000)

–Factory Warranty

–Limited Manufacturers in the market

currently – number is growing

–Dedicated Fuel – requires home base

fueling in many circumstances

Vehicle Maintenance

• Increased time between maintenance

intervals

• No modification required to shops

• Efficient training/certification process for

maintenance and refueling

Safety

Myths regarding propane vehicles vs. other

fueled vehicles

–Storage tanks

–Emergency valves

–Risk of ignition compared to gasoline

Public Refueling

• AFDC website is an excellent source for

propane motor fuel stations

• Public Stations with appropriate pricing is

limited but growing

• Reminder – awareness of how retailer is

pricing propane autogas

• Current Code Limitations

Consumer Education and Awareness

• Need Increased vehicles on the road

• Inform consumers regarding safety

• Educate consumers on the economics

• Educate consumers on the benefits to US

Questions?