Gas Technology Institute & ET Environmental - CNG/LPG Garage Maintenance Considerations

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Are you interested in the considerations for garage and maintenance shops when using CNG & LPG? Learn about the considerations of using a garage to maintenance CNG & LPG and the guidelines that need to be followed.

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Gas Technology Institute & ET Environmental - CNG/LPG Garage Maintenance Considerations

  1. 1. CNG, LNG, and LPG in Repair and Maintenance Facilities: Code Issues and Compliance > February 2014
  2. 2. Natural Gas Overview Safety Identify Objectives & Codes Facility Audit Code Requirements Modifications Resources 2
  3. 3. 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 3
  4. 4. 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) 4
  5. 5. 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 5
  6. 6. Code Requirement- Major vs. Minor Major vs. Minor Repair Activities: Hazard Separation • With proper separation, only major repair areas require modification per code 6
  7. 7. Code Requirements- Ventilation Mechanical Ventilation Requirements: *allows for non-continuous ventilation with proper gas detection 7
  8. 8. Code Req. -Electric Classification Electrical & Hazardous Area Classification: • Hazardous area classification can be avoided by supplying continuous ventilation per NFPA 30A and 70 8
  9. 9. Code Req. -Electric Classification Electrical & Hazardous Area Classification: • Hazardous area classification can be avoided by supplying continuous ventilation per NFPA 30A and 70 9
  10. 10. 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 alarms 2. Turn off garage heating elements 3. Turn on emergency ventilation if interlocked 10
  11. 11. Code Topic – Gas Detection 11
  12. 12. Code Req. – Heat Producing Appliances Heat Producing Appliances: •Gas or oil fueled heaters must be install 18” above grade for conventional fuel repair garages. 12
  13. 13. 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. 13
  14. 14. Steps to Determine if Garage Modifications are Necessary 14
  15. 15. 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/P DFs/GuidelinesDocumentFinal.pdf) • Wisconsin State Energy Office: Natural Gas for Transportation Vehicle Repair Garage Guidelines (http://www.stateenergyoffice.wi.gov/docview.asp?do cid=24889&locid=160) 15
  16. 16. 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/B uildingCodesRegulations.aspx 16
  17. 17. 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=80b145e2-4b2946f9-a7aa-047009b0342f • SPS 316 recognizes NEC/ NFPA 70 2008 for electrical 17
  18. 18. 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 18
  19. 19. 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 19
  20. 20. Propane Overview Safety Identify Objectives & Codes Facility Audit Code Requirements Modifications Resources 20
  21. 21. Safety Physical 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) 21
  22. 22. 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) 22
  23. 23. 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 23
  24. 24. 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 24
  25. 25. Code Requirements- Ventilation Mechanical Ventilation Requirements: • There are no additional ventilation requirements for LPG facilities 25
  26. 26. Code Req. -Electric Classification Electrical & Hazardous Area Classification: 26
  27. 27. Code Req. – Sources of Ignition Source of Ignition: •A major concern of ignition source in repair garages is space heater design. 27
  28. 28. 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 28
  29. 29. 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 29
  30. 30. Steps to Determine if Garage Modifications are Necessary Facility Audit Codes Shop Mods • Is the existing facility code compliant? • Are shop activities minor or major? • Is the shop public or private? • What codes will the AHJ use for compliance and inspection? • • • • Ventilation Hazardous Area Classification Sources of Ignition Defueling System and Vehicle Prep Procedures 30
  31. 31. Resources Additional Reading: • Propane Autogas: Repair and Maintenance Facility Requirements, Propane Education & Research Council (PERC), 2013. (http://www.autogasusa.org/uploadedFiles/Fuel/Resour ces/Training_Manuals/Repair_and_Maintenance%20Fac ility_Requirements.pdf) 31
  32. 32. 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/B uildingCodesRegulations.aspx 32
  33. 33. 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=80b145e2-4b2946f9-a7aa-047009b0342f • SPS 316 recognizes NEC/ NFPA 70 2008 for electrical 33
  34. 34. 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 34
  35. 35. 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 35
  36. 36. Acknowledgement of Support 36
  37. 37. FEBRUARY 5, 2014 WISCONSIN CLEAN CITIES WEBINAR NGV MAINTENANCE FACILITIES Code Related Modifications For NGVs In Existing Maintenance Facilities Steve Arnold, P.E. Senior Design Manager
  38. 38. TODAYS AGENDA  Wisconsin specific requirements and compliance strategies  Case Studies  Costs  Q&A
  39. 39. 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
  40. 40. 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
  41. 41. 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
  42. 42. MAINTENANCE FACILITES GARAGE RETROFITS FOR NGVs  Every shop is unique  Consult a professional  Code compliance is only one component • Operations • Training
  43. 43. NGV MAINTENANCE FACILTY EVALUATION 1) 2) 3) 4) Ventilation Gas Detection Heating Systems Electrical Systems and Components  Existing Conditions and Code Triggers  Other items that may be applicable (for now, assume “Major Repair Garage”)
  44. 44. NGV MAINTENANCE FACILITY VENTILATION TWO DISTINCT VENTING CRITERIA 1) 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)
  45. 45. NGV MAINTENANCE FACILITY VENTILATION 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
  46. 46. NGV MAINTENANCE FACILITY DETECTION      Detector heads – where and how many? Tied to a fire alarm system or monitoring? Calibration Relay Panel LNG 46
  47. 47. NGV MAINTENANCE FACILITY HEAT & FLAMES     Areas of ignitable concentrations Non-compliant heaters Other non-compliant appliances Compliant heat • Floor Radiant • Low Intensity Radiant • Air handler* • Steam
  48. 48. NGV MAINTENANCE FACILITY HEATERS
  49. 49. NGV MAINTENANCE FACILITY ELECTRICAL Classified Zone “the area with 18” of the ceiling shall be designated a Class 1, Division 2 hazardous location ……… Except in Wisconsin Ref SPS 316.511 effective Dec 1, 2013
  50. 50. NGV MAINTENANCE FACILITY ADJACENT 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
  51. 51. 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
  52. 52. Existing Building & Conditions  WI has adopted the 2009 IEBC  Identify “triggers” for current code compliance  Alteration Level and Change in Occupancy
  53. 53. 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”
  54. 54. NGV MAINTENANCE FACILITY HEAT < 750 °F and no open flames Gas Detection required for LNG VENTILATION Required at 5 ACH Interlocked to Lighting CNG Only (NA tot LNG) Electrical classified areas must be addressed for projects outside of Wisconsin Continuous Interlocked to Gas Detection GAS DETECTION
  55. 55. MINOR REPAIR GARAGES MINOR 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.
  56. 56. 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)
  57. 57. MINOR REPAIR GARAGES Electrical - Ceiling Unclassified Heat No 750 °F and open flame requirements Gas Detection required for LNG Ventilation - Required at 5 ACH (or petition for a variance) Interlocked to lighting CNG Only (NA to LNG) Continuous Interlocked to Gas Detection
  58. 58. 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
  59. 59. 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
  60. 60. 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
  61. 61. CASE STUDIES Waste 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
  62. 62. CASE STUDIES Kwik Trip  Separated 1 Bay Major NGV Repair & LNG,  Gas detection  Purge venting  Compliant Heating  Electrical removed ceiling  Plugged floor drain  Additional lighting
  63. 63. CASE STUDIES City of Milwaukee  Separated 6 Bays Major Repair for NGVs  Partition Walls  Gas detection  Purge venting  Air handler heating  Lighting rated for classified area
  64. 64. 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
  65. 65. COSTS Cont. Some examples of cost information …… Assessment and Design Professional Services $ Lump $25,000 - $40,000 Sum Assessment, Design, Permitting, & Construction Support $ Ventilation Exhaust fans EA Ducting LF $8,200 - $9,200 $45-$60 Ventilation required for 5 ACH. Includes Mechanical, Electrical, Roof Framing & Roofing Work. Exposed non-insulated interior duct & fittings 65
  66. 66. COSTS Cont. Gas Detection Detectors and Controller LNG – Pit Detectors Heating Infrared Tube heaters $ 1 $30,000-$45,000 Equipment, installation, and electrical. EA $3,500-$5,000 Dependent on floor slab and underground scope of work. $ $/SF $12-$17 Includes electrical
  67. 67. COSTS Cont. Electrical Shunt Trip 30A Breakers Other Separation Wall Design Management $ EA $525- $650 Assumes that space is available in the panel $ SF $18 - $25 5% to 10% Metal Stud with metal panels Schematic, design mgmt, permitting, permit fees
  68. 68. COSTS Cont.  Other cost items are addressed in more detail in the guidelines document. • • • • Misc Demolition Lighting LNG Floor Drains Roof Access Ladder
  69. 69. 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
  70. 70. QUESTIONS? Steve Arnold, P.E. Senior Design Manager
  71. 71. Contact Information ET Environmental Corporation, LLC Website: www.etenv.com Steve Arnold sarnold@etenv.com 708-478-8200 Jeff Lamoureux jlamoureux@etenv.com 208-928-7361 Wisconsin Department of Administration - State Energy Office Website: http://stateenergyoffice.wi.gov/ Maria Redmond, Senior Analyst & Program Manager, Transportation Fuels Maria.Redmond@wisconsin.gov 608-266-1521

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