PLANNING TO CONVERT A CONVENTIONAL REPAIR SHOP FOR MAINTENANCE OF NATURAL GAS VEHICLES An inside look at codes, compliance, and cost

Transcription

1 PLANNING TO CONVERT A CONVENTIONAL REPAIR SHOP FOR MAINTENANCE OF NATURAL GAS VEHICLES An inside look at codes, compliance, and cost September 17, 2013 Jeff Lamoureux, PE

2 Today s Agenda Major Repair Shops Focus on Major Repair Garages Overview NG properties and applicable codes Requirements and compliance strategies Case Studies Costs Q&A

3 Presenter Qualifications 23 years experience Planning Commission Member Managed 50+ NGV related projects in the past 6 years with ET Jeff Lamoureux, PE Senior Design Manager 3

4 Natural Gas Properties Natural Gas differs from gasoline and diesel fuels Natural gas is lighter-than-air and is in a gaseous form at atmospheric conditions The mixture of natural gas in air that will support combustion - between 5% and 15% by volume NG has an ignition temperature of around 900 to 1,200 F Typically odorized for safety (CNG). LNG is non odorized

5 LNG Natural Gas Properties -260 F Gaseous vapors are heavier than air below -170 F Potential Hazards to Mitigate Flammability Asphyxiant Gas High Pressure (CNG) Cryogenic (LNG)

6 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

7 Who Applies Code? Qualified design professional prepares permit documents (P.E.) AHJ - Authority Having Jurisdiction Local fire official will review Building official may review items such as structural modifications or separation wall Electrical and mechanical trade permits (OTC) Code interpretations?

8 Maintenance Facility Retrofits Every shop is unique Code compliance is only one component Operations Training Consult a professional

9 Facility Evaluation Ventilation Gas Detection Heating Systems Electrical Systems and Components Other Considerations Migration of gas LNG Spill Mitigation Existing conditions and code required upgrades

10 Facility Ventilation Clarification of Venting Criteria Mechanical ventilation for NGV facilities Required for NGV s, not Diesel or Gasoline Minimum ventilation for occupied space Same for Natural Gas and conventional fuels

11 Facility Ventilation Garages for the repair of vehicles which use CNG, LNG or other lighter-than-air motor fuels shall be provided with an approved mechanical ventilation system.

12 Approved system includes: 5 air changes per hour (ACH) Continuous operation, interlocked to detection, or interlocked to lights Uniform airflow outlets at high point, inlets at floor Exception: Facility Ventilation Natural ventilation when approved

13 Compliance Strategies Continuous ventilation by fans at high point of roof with intake louvers in sidewalls near floor - OR - Facility Ventilation Interlock to detection system so emergency ventilation will operate only when gas is detected. This will reduce heating load and ongoing heating costs.

14 Facility Detection NFPA 30A Section Where repairing NGVs fueled by non-odorized gas (LNG) a gas detection system is required Detection is required in pits for LNG Detection can be used to control NGV related ventilation Reference: NFPA 30A Section & IBC

15 Compliance Strategy Facility Detection Install detection system where LNG vehicles are present Detection may be desirable where CNG vehicles are present to reduce heating load or as an enhanced safety measure

16 Heaters Where major repairs are conducted on NGVs, open flame heaters or heating equipment with surface temperatures in excess of 750º F shall not be permitted in areas subject to ignitable concentrations of gas.

17 Compliance Strategies Heaters Removal of appliances with pilot or open flame Replace with compliant heaters Typically radiant heaters rated for hazardous location Steam, hot water, forced air if designed properly

18 Electrical

19 Electrical Classified Zone In major repair garages where CNG vehicles are repaired or stored, the area with 18 of the ceiling shall be designated a Class 1, Division 2 hazardous location

20 Classified zone (cont.) Electrical 18 at the floor is also Class 1 Div. 2 for Gasoline Vehicles Maintenance pits are classified areas but with the same criteria as Diesel and Gasoline Shops

21 Exception: Electrical Not required where continuous ventilation of at least 4 ACH is provided.

22 Compliance Strategies Relocate electrical outside classified zone Use equipment permitted in classified zone (XP) Continuous ventilation Electrical

23 Additional Items to Consider 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

24 Additional Items to Consider Floor drains Provisions must be made to prohibit LNG from entering drain conveyance system Potential triggers for code compliance Overhead cranes may be an ignition source, confirm motors and contactors are not within classified space

25 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

26 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

27 Waste and Recycling Vehicle Garage 7 bay major repair garage Gas detection Purge venting Infrared heating Case Studies Electrical rated for Classified area at ceiling Sealed separation walls at office and wash bay

28 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

29 City of Milwaukee Case Studies Separated 6 bays major repair for NGVs Partition walls Gas detection Purge venting Air handler heating Lighting rated for Classified area

30 Every shop is different Costs Choice of strategy varies depending on operations, interpretations, etc. Construction costs only Does not consider design and permitting Does not consider operations costs Assessment and Design $ Professional Services Lump Sum $25,000 - $40,000 Assessment, Design, Permitting, & Construction Support

31 Cost Example So. California Inland Empire Construct demising wall and limit improvements (4,200 sf) Mechanical ventilation for NGV shop Replace heaters with low intensity radiant tube heaters Gas detection Construction only (competitive bid) = $235,000

32 Cost Example Oregon Greater Portland Approx. 6,500 sf Mechanical exhaust ventilation for NGV shop Replace heaters with low intensity radiant tube heaters Gas detection Lower electrical in ceiling Lighting upgrades (not req. for NGV compliance) Construction only (cost plus) = $246,000

33 Cost Example So. California Los Angeles Metro Region Mechanical exhaust ventilation for NGV shop Replace heaters with low intensity radiant tube heaters Continuous ventilation & detection Backup power for emergency systems Lighting upgrades (not req. for NGV compliance) Construction only (cost plus) = $656,000

34 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

35 Questions? Jeff Lamoureux, PE, Senior Design Manager