MS 1204:2013

Compressed natural gas (CNG) refuelling stations - Code of practice (Second revision)

ICS: 75.060 Descriptors: code of practice, compressed natural gas (CNG), refuelling station

© Copyright 2013

DEPARTMENT OF STANDARDS MALAYSIA

MALAYSIAN STANDARD

DEVELOPMENT OF MALAYSIAN STANDARDS The Department of Standards Malaysia (STANDARDS MALAYSIA) is the national standards and accreditation body of Malaysia. The main function of STANDARDS MALAYSIA is to foster and promote standards, standardisation and accreditation as a means of advancing the national economy, promoting industrial efficiency and development, benefiting the health and safety of the public, protecting the consumers, facilitating domestic and international trade and furthering international cooperation in relation to standards and standardisation. Malaysian Standards (MS) are developed through consensus by committees which comprise balanced representation of producers, users, consumers and others with relevant interests, as may be appropriate to the subject at hand. To the greatest extent possible, Malaysian Standards are aligned to or are adoption of international standards. Approval of a standard as a Malaysian Standard is governed by the Standards of Malaysia Act 1996 [Act 549]. Malaysian Standards are reviewed periodically. The use of Malaysian Standards is voluntary except in so far as they are made mandatory by regulatory authorities by means of regulations, local by-laws or any other similar ways. For the purposes of Malaysian Standards, the following definitions apply: Revision: A process where existing Malaysian Standard is reviewed and updated which resulted in the publication of a new edition of the Malaysian Standard. Confirmed MS: A Malaysian Standard that has been reviewed by the responsible committee and confirmed that its contents are current. Amendment: A process where a provision(s) of existing Malaysian Standard is altered. The changes are indicated in an amendment page which is incorporated into the existing Malaysian Standard. Amendments can be of technical and/or editorial nature. Technical corrigendum: A corrected reprint of the current edition which is issued to correct either a technical error or ambiguity in a Malaysian Standard inadvertently introduced either in drafting or in printing and which could lead to incorrect or unsafe application of the publication. NOTE: Technical corrigenda are not to correct errors which can be assumed to have no consequences in the application of the MS, for example minor printing errors. STANDARDS MALAYSIA has appointed SIRIM Berhad as the agent to develop, distribute and sell Malaysian Standards. For further information on Malaysian Standards, please contact: Department of Standards Malaysia OR SIRIM Berhad Ministry of Science, Technology and Innovation (Company No. 367474 - V) Level 1 & 2, Block 2300, Century Square 1, Persiaran Dato’ Menteri Jalan Usahawan Section 2, P. O. Box 7035 63000 Cyberjaya 40700 Shah Alam Selangor Darul Ehsan Selangor Darul Ehsan MALAYSIA MALAYSIA Tel: 60 3 8318 0002 Tel: 60 3 5544 6000 Fax: 60 3 8319 3131 Fax: 60 3 5510 8095 http://www.standardsmalaysia.gov.my http://www.sirim.my E-mail: central@standardsmalaysia.gov.my E-mail: msonline@sirim.my

MS 1204:2013

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CONTENTS

Page Committee representation .........................................................................................................iv Foreword .................................................................................................................................... v SECTION 1: SCOPE AND GENERAL ...................................................................................... 1 1.1 Scope ............................................................................................................................ 1 1.2 Normative references ................................................................................................... 1 1.3 Terms and definitions ................................................................................................... 2 1.4 Additional requirements for public refuelling stations ................................................... 5 1.5 Approvals ...................................................................................................................... 5 1.6 Supply enquiries ........................................................................................................... 5 SECTION 2: COMPONENTS .................................................................................................... 6 2.1 General ......................................................................................................................... 6 2.2 Gas-fired appliances ..................................................................................................... 6 2.3 Compressors ................................................................................................................ 6 2.4 Piping (including flexible piping/hoses and tubing) ...................................................... 8 2.5 Valves, piping and tubing components ......................................................................... 8 2.6 Safety devices for pressure protection ......................................................................... 9 2.7 Pressure gauges .......................................................................................................... 9 2.8 Electrical equipment and wiring .................................................................................... 9 2.9 Refuelling hose assemblies ........................................................................................ 14 2.10 Refuelling connectors ................................................................................................. 14 2.11 Refuelling hose assembly breakaway couplings ........................................................ 14 SECTION 3: INSTALLATIONS ................................................................................................ 16 3.1 General ....................................................................................................................... 16 3.2 Location, security and physical protection of equipment ............................................ 16 3.3 Refuelling station elements ........................................................................................ 19 3.4 Inlet gas supply equipment ......................................................................................... 20 3.5 Gas compression equipment ...................................................................................... 20 3.6 Compressed gas storage systems ............................................................................. 20 3.7 Dispensers/fill posts .................................................................................................... 21 3.8 High pressure discharge system ................................................................................ 22 3.9 Safety and control systems ........................................................................................ 24 3.10 Power and control electrical systems ......................................................................... 25 SECTION 4: TESTING AND COMMISSIONING .................................................................... 26 4.1 General ....................................................................................................................... 26 4.2 Station compliance documentation ............................................................................ 26

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CONTENTS (continued)

Page 4.3 Commisioning documentation and records ................................................................ 26 SECTION 5: OPERATION AND MAINTENANCE .................................................................. 27 5.1 General ....................................................................................................................... 27 5.2 Establishment of procedures ...................................................................................... 27 5.3 Supervision ................................................................................................................. 30 5.4 Records ...................................................................................................................... 30 5.5 Specific operating procedures .................................................................................... 30 5.6 Specific maintenance, inspection and testing ............................................................ 31 Table 1 Safety distances from buildings and boundaries to gas storage unit .................. 17 Figure 1 Hazardous area delineation for public refuelling stations .................................... 10 Figure 2 Hazardous area delineation (enclosed compressor) for public refuelling stations ................................................................................................................. 11 Figure 3 Hazardous area delineation (outdoor installation) for public refuelling stations ................................................................................................................. 12 Figure 4 Hazardous area delineation for dispenser at public refuelling stations ............... 13 Figure 5 Deflection wall ...................................................................................................... 18 Figure B1 Piping isometric .................................................................................................... 37 Figure B2 Piping schematic .................................................................................................. 38 Figure C1a) Typical layout for a mother stations ..................................................................... 39 Figure C1b) Typical layout for a daughter station .................................................................... 39 Annex A Approving Authority .............................................................................................. 35 Annex B Example of gas inlet train ..................................................................................... 37 Annex C Typical layout of mobile storage units .................................................................. 39 Annex D Refuelling instructions and procedures ................................................................ 40 Annex E Examples of signs and notice .............................................................................. 41

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CONTENTS (concluded)

Page Annex F Checklist for putting the station into service and annual safety inspections of refuelling stations ................................................................................................. 45 Annex G Example of hot work permit ................................................................................. 47

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Committee representation The Industry Standards Committee on Petroleum and Gas (ISC H) under whose authority this Malaysian Standard was developed, comprises representatives from the following organisations: Association of Consulting Engineers Malaysia Association of Malaysian Oil and Gas Engineering Consultants Department of Occupational Safety and Health Malaysia Department of Standards Malaysia Federation of Malaysian Manufacturers - Malaysian Industrial Gases Manufacturers Group Jabatan Bomba dan Penyelamat Malaysia Jabatan Pengangkutan Jalan Malaysia Kastam Diraja Malaysia Malaysian Gas Association Malaysian Palm Oil Board Malaysian Plastics Manufacturers Association Ministry of Domestic Trade, Co-operatives and Consumerism Ministry of International Trade and Industry Petroliam Nasional Berhad PETRON Malaysia Refining & Marketing Bhd PETRONAS Technical Services Sdn Bhd Shell Malaysia Trading Sdn Bhd SIRIM Berhad (Secretariat) Suruhanjaya Tenaga The Institution of Engineers, Malaysia Universiti Teknologi Malaysia Universiti Teknologi PETRONAS The Working Group on Compressed Natural Gas Compressor Refuelling Station which developed this Malaysian Standard consists of representatives from the following organisations: Asia Pacific Natural Gas Vehicles Association Department of Environment, Malaysia Department of Occupational Safety and Health Malaysia Dewan Bandaraya Kuala Lumpur Gas Malaysia Berhad Jabatan Bomba dan Penyelamat Malaysia Majlis Bandaraya Shah Alam Ministry of Domestic Trade, Co-operatives and Consumerism PETRONAS Dagangan Berhad Sime Darby Industrial Sdn Bhd SIRIM Berhad (Secretariat) SIRIM QAS International Sdn Bhd Suruhanjaya Tenaga UMW Industrial Power Sdn Bhd Universiti Teknologi Malaysia

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FOREWORD This Malaysian Standard was developed by the Working Group on Compressed Natural Gas Compressor Refuelling Station under the authority of the Industry Standards Committee on Petroleum and Gas. This Malaysian Standard is the second revision of MS 1204, Code of practice for CNG compressor refuelling stations: On site storage and location of equipment. Major modifications in this revision are as follows: a) components of the refuelling station have been incorporated as Section 2; b) table 1, the safety distances from buildings and boundaries to gas storage unit for total

storage capacity of above 1100 m3 has been amended; c) description and location of deflection wall have been incorporated as Table 1 and Figure

5; d) testing and commission have been incorporated as Section 4; e) operation and maintenance have been incorporated as Section 5; f) the example of gas inlet train has been incorporated as Annex B; g) the examples of signs and notice have been incorporated as Annex E; h) the checklist for putting the station into service and annual safety inspections of refuelling

stations has been incorporated as Annex F; and i) the example of hot work permit has been incorporated as Annex G. This Malaysian Standard cancels and replaces MS 1204:2001. Compliance with a Malaysian Standard does not of itself confer immunity from legal obligations.