CECOD suggestion for Directive 1999/92/EC ATEX zoning around Gasoline/diesel/LPG and CNG/LNG dispensers

Transcription

1 CECOD suggestion for Directive 1999/92/EC ATE zoning around Gasoline/diesel/LPG and CNG/LNG dispensers G Version: 1.1 beta3 for CNG/LNG and H2 Date: 29/01/2015

2 Document Identification Title CECOD suggestion for ATE zoning (directive 1999/92/EC) around EN and EN and CNG dispensers on stations in free air Reference G Prepared by SG6 Creation Date 16/12/2013 Version 0.a Document Status comment Draft draft revisions are from 0a to 0z... Final 1.1b3 released revisions are from 1 and up History of Changes Date Author Version Description of Changes 16/12/2013 Ph.CLOUTIER 0.a Created for CECOD SG6 brainstorm 21/01/2014 Ph.CLOUTIER 0.b Added T3 class or better for all zones 10/04/2014 Ph.CLOUTIER 0.c Completed with calculations 14/04/2014 Ph.CLOUTIER 0.d Added forecourt arrangement suggestions 05/06/2014 Ph.CLOUTIER 0.e Small adjustments in editorials (yellow) 06/08/2014 Ph.CLOUTIER 1.0 First valid released revision 08/09/2014 Ph.CLOUTIER 1.1 Disclaimer adjustment 29/09/2014 Ph.CLOUTIER 1.1 beta2 Adjustement for CNG and H2 29/01/2015 Ph.CLOUTIER 1.1 beta3 Including LNG in the CNG chapter Revised By Name Title/Role Ola THORKELSSON (Wayne) SG6 chair Mike MELNYK (GVR) Publishing Destination Level Date Authorized by (name) Signature Study Group only SG 15/09/2014 Ola Thorkelsson draft CHAIR Internal TC 15/09/2014 Philippe Cloutier draft CHAIR Public CECOD CHAIR 15/09/2014 Informative to Public on CECOD Website As per GA decision draft

3 DISCLAIMER The information contained in this document is provided as is and corresponds to the best knowledge available. It is the CECOD study group work to build a common understanding without disclosing any proprietary information or know-how. CECOD assumes no responsibility due to any misuse of this information, and takes no responsibility on any consequences. It is the responsibility of the person or company using this document to endorse fully the design of their products, processes and services. It is the responsibility of the person or companies legally in charge of the initial and continued compliance with applicable directives and laws and using this document to check and address any legal issue such related to (list is not limitative) - Liability - Compliance to applicable directives and laws (from transposition or national specific) - Patent infringement - H&S issues for public and workers - Consequences of design choices, design changes, impact on check procedures and instructions The use of this document is only allowed if person or company using this document fully takes ownership of legal and commercial responsibility of resulting study, product, service, and will not seek any liability of CECOD. The person or company also takes all and any necessary steps to prevent any liability to CECOD.

4 INDE Scope 1) Domain 2) References to standards 3) Terms and acronyms 4) Suggestion for petrol and diesel dispensers using EN ) Suggestion for LPG dispensers using EN ) Suggestion for CNG and LNG dispensers (ISO standard pending) 7) Suggestion for H 2 dispensers 8) Forecourt arrangement and management suggestions 1/42

5 SCOPE: Dispensers made by CECOD members are subject to ATE 94/9/EC approvals, conducted with reference to harmonized EU standards. As such, CECOD members manufacture ATE compliant dispensers - Gasoline and diesel: using harmonized standard EN LPG dispensers: using harmonized standard EN Both standards comprise an annex ZA for correspondence between the clauses in the standard and the essential requirements of the ATE directive 94/9/EC for products. On the other hand, specific ATE directive for working places (1992/92/EC) is transposed into national requirements. Such transposition either leaves definition of zones to owner of site, or imposes some zoning constraints. When zoning constraints around dispensers are imposed by national legislation (taken to transpose 1999/92/EC), it is assumed that legislators have done their own risk assessment and calculations to establish requirements in the most adequate way. When zoning constraints around dispensers are left to owner by national legislation (taken to transpose 1999/92/EC), it is not always easy for owners to establish their own zoning, as this requires very good understanding of the filling process and existing hazard. The purpose of this guide is to help owners establish their own assessment for 1999/92/EC ATE zoning on site. The purpose of this guide is also to bring CECOD knowledge and assessment to EU member state legislators, to help them establish their own risk assessment when they impose the zoning for 1999/92/EC in the national legislation and/or rules. The use of this guide is only allowed if person or company using this document fully takes ownership of legal and commercial responsibility of resulting study, risk assessment, decision and any consequences, and will not seek any liability of CECOD or CECOD members, either companies or individuals. The person or company using this guide as a whole or only part also takes all and any necessary steps to prevent any liability to CECOD. 2/42

6 1) Domain Petrol stations in Europe sites for gasoline, diesel, LPG and CNG, in free open air. Gasoline/diesel and LPG dispensers are marked in the following way: 2) References to standards and Directives EN ATE series EN EN Directive 94/9/EC (ATE) - concerning equipment and protective systems intended for use in potentially explosive atmospheres Directive 1992/92/EC (ATE working places) - concerning Protection of Workers at Risk from Potentially Explosive Atmospheres 3) Terms, acronyms and symbols To be completed 3/42

7 4) Suggestion for petrol and diesel dispensers using EN Recommendation for zoning assessment in application of Directive 1999/92/EC (on minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmosphere) 4.1) General In application of 1999/92/EC directive, temperature class T3 or better is required, and the following zones for gas group IIA, are deemed enough for open air sites using EN certified dispensers: - Idle dispenser: zones defined in EN (see manufacturer s manual) - Installed dispenser: the 4.2 permanent zones are added to the idle dispenser zoning - Dispenser in action: the 4.3 active zones are added to the installed dispenser zoning Note: - Consider aircrafts and boats as vehicle. Consider fuels for these as gasoline or diesel. - Table 1: Known possible configurations in EU countries. Dispensers with flowrates, fuels, application and possible related standard(s) other than EN Only for information. Flowrate 40 l/mn Table 1 > 40 l/mn to 80 l/mn > 80 l/mn to 130 l/mn > 130 l/mn to 200 l/mn Fuel dispensed Most common flowrate for cars and motorcycles, also for boats and light aircrafts Most common flowrate for small trucks, tractors, boats and aircrafts Most common flowrate for big trucks, heavy work machines, and boats Special flowrate for big trucks, heavy machines and boats Gasoline without VR2 system Gasoline with VR2 system Diesel without VR2 system YES YES YES (special applications) YES NO See footnote NO See footnote YES (special applications) NO See footnote YES YES YES YES Diesel is considered as not needing VR2, even if technically possible, as vapor pressure is low Footnote: EN limits flow rate to (38,0 ± 1,0) l.min -1, for VR2 4/42

8 4.2) 1999/92/EC recommended PERMANENT zones associated to gasoline/diesel dispensers description NH zone Gasoline (note 1) hose reach From dispenser to maximum extend of hose reach, from forecourt floor up to 0,80 meter height Notes: - this zone is recommended because of potential drops or small spillages of gasoline fuel on forecourt m is maximum starting height for disable access to payment terminals Diesel (note 2) hose reach From dispenser to maximum extend of hose reach, from forecourt floor up to 0.25 meter height Note: this zone is recommended because of potential drops or small spillages of diesel fuel on forecourt Electronic head (non hazardous zone) of EN certified apparatus above 0.8 meter from forecourt floor (calculator, payment terminal, display) 5/42

9 4.3) 1999/92/EC recommended ACTIVE zones associated to gasoline/diesel dispensers Dispenser is in action starting from the moment the nozzle is inserted in the vehicle filler neck (start of transaction) till the nozzle is removed from the filler neck of the vehicle (end of flow). description NH zone GASOLINE (note 1) with no VR2 system When flowrate is 40 liters per minute - interface to vehicle, R 30 cm - interface to vehicle, R 65 cm - Interface to vehicle, R 125 cm - projection to floor of interface sphere R=125 Note: special extra grounding arrangement required between dispenser and boat or aircraft being refueled GASOLINE (note 1) with active VR2 system When flowrate is 40 liters per minute - interface to vehicle, R 10 cm - interface to vehicle, R 20 cm - Interface to vehicle, R 30 cm - projection to floor of interface sphere R=30 Note: special extra grounding arrangement required between dispenser and boat or aircraft being refueled 6/42

10 description NH zone GASOLINE (note 1) with no VR2 system When flowrate is > 40 liters per minute and 80 liters per minutes - interface to vehicle, R 40 cm - interface to vehicle, R 90 cm - Interface to vehicle, R 175 cm - projection to floor of interface sphere R=175 Note: special extra grounding arrangement required between dispenser and vehicle, boat or aircraft being refueled GASOLINE (note 1) with no VR2 system When flowrate is > 80 liters per minute and 130 liters per minutes - interface to vehicle, R 50 cm - interface to vehicle, R 115 cm - Interface to vehicle, R 225 cm - projection to floor of interface sphere R=225 Note: special extra grounding arrangement required between dispenser and vehicle, boat or aircraft being refueled GASOLINE (note 1) with no VR2 system When flowrate is > 130 liters per minute and 200 liters per minutes, - interface to vehicle, R 65 cm - interface to vehicle, R 140 cm - Interface to vehicle, R 275 cm - projection to floor of interface sphere R=275 Note: special extra grounding arrangement required between dispenser and vehicle, boat or aircraft being refueled 7/42

11 description NH zone DIESEL (note 2) with no VR2 system When flowrate is 40 liters per minutes - interface to vehicle, R 5 cm - interface to vehicle, R 10 cm - interface to vehicle, R 20 cm - projection to floor of interface sphere R=20 Note: special extra grounding arrangement required between dispenser and aircraft being refueled DIESEL (note 2) with no VR2 system When flowrate is > 40 liters per minute and 80 liters per minutes - interface to vehicle, R 10 cm - interface to vehicle, R 20 cm - interface to vehicle, R 30 cm - projection to floor of interface sphere R=30 Note: special extra grounding arrangement required between dispenser and aircraft being refueled DIESEL (note 2) with no VR2 system When flowrate is > 80 liters per minute and 200 liters per minutes - interface to vehicle, R 10 cm - interface to vehicle, R 25 cm - interface to vehicle, R 50 cm - projection to floor of interface sphere R=50 Notes: - special extra grounding arrangement required between dispenser and aircraft being refueled - special extra grounding arrangement recommended between dispenser and vehicle or boat being refueled 8/42

12 Note 1: gasoline or similar fuels having a Reid vapor pressure of 27,6 kilopascals or more (note 3). Examples of similar fuels are (non exhaustive list) Unleaded, leaded, regular (any octane) Unleaded with any proportion of Ethanol or Methanol (any octane), Avgas (any quality) Note 2: diesel or similar fuels having a Reid vapor pressure of less than 27,6 kilopascals (note 3). Examples of similar fuels are (non exhaustive list) Kerosene Bio-diesel (any proportion of bio) heating fuel Jet fuel (e.g.: Jet A1) Mineral spirit Note 3: Reid vapor pressure reference taken in Directive 94/63/EC of 20 December 1994, on the control of volatile organic compound (VOC) emissions resulting from the storage of petrol and its distribution, clause 2 (a) Note for all filling stations: Adequate positioning of vehicle/boat/aircraft being refilled will secure active zones away from dispenser and its electronic NH zones. Is deemed adequate any association of one or more of the following steps: proper instructions and signage to the end user, the driver or the pilot paint on forecourt to properly park vehicle or aircraft before fill side stones and/or floor barriers to position vehicle Pillars and/or beams to properly dock boat and limit movement during fill Note for aircraft filling stations: Special care must be taken in considering possible static electricity due to propellers, turbines, air flow around aircraft and length of hose. Grounding sequence of aircraft before fill starts must be carefully understood to avoid any spark at introduction of nozzle spout in tank filler neck. Aircraft must be secured so no unwanted movement will occur during fill. Note for boat filling stations: Special care must be taken in considering possible static electricity due to high speed fill, length of hose and possible movement of boat not allowing for a permanent contact between nozzle spout and filler neck. Grounding sequence of boat before fill starts must be carefully understood to avoid any spark at introduction of nozzle spout in tank filler neck, or during fill. In this case, special care must be taken to consider surface of water as forecourt level reference for permanent zoning, and secure possible accumulation of vapors under filling deck/pontoon. 9/42

13 4.4) Rationals for zoning scenario of paragraph 4.3 Concept 1: G Zoning for 1999/92/EC around Vapors of gasoline expelled from car filler neck are falling to the floor at around 40 cm/second (Butane worst case scenario, butane is the light fraction of gasoline). Assumption is LEL is 0.7% for gasoline. EN establishes zone in relation with frequency of exposure. That approach might be fragile when considering petrol stations with public/consumers presence. CECOD approach is to consider: - 0 for any potential concentration above LEL - 1 for any potential concentration above 20% of LEL - 2 for any potential concentration above 5% of LEL Concept 2: The speed the gasoline vapors are expelled creates concentric spheres of hazard (Z0, Z1 and Z2). Such spheres are limited on one side by the vehicle cladding. In zone 2, it is considered that expelling speed is not enough to create the upper half of the sphere. Sphere of zone 0 zone around the vapor generating point, where vapors are above LEL during fill. Vapors leaving this sphere shall have a concentration of less than LEL during fill. Sphere of zone 1 zone (excluding zone 0 above) around the vapor generating point, where vapors are above 20% of LEL during fill. Vapors leaving this sphere shall have a concentration of less that 20% of LEL during fill Sphere of zone 2 zone (excluding zone 0 and zone 1 above) around the vapor generating point, where vapors are above 5% of LEL during fill. Vapors leaving this sphere shall have a concentration of less that 5% of LEL during fill. Projection to floor of interface sphere r=xx zone projected from given zone 2 sphere down to the forecourt floor, as zone 2 extends to floor by gravity (vapor heavier than air) Concept 3: Sphere radius calculation a) Even if full sphere is considered as hazardous, only consider ¼ of sphere surface for vapor escape route - ½ because vapors are dropping to the floor, - ½ because dissipation is limited on one side by vehicle cladding b) As a consequence, surface of mix of vapors with air at bottom border of sphere is only 25% of total surface of sphere. Sphere surface is S = 4 π R 2 10/42

14 Bottom border surface of sphere is BS = π R 2 where R is the radius of the sphere in meters, and BS = surface in m 2 of mixing interface surface for vapor with fresh air. Outgoing stream of vapors expelled from the vapor generating point and passing this surface is migrating to the floor at 0.4 m/s (butane light fraction worst case scenario for gasoline). If filling flowrate is V (in liters per second), amount of vapors expelled during the fill process is same. For gasoline These vapors are considered saturated at 100% as a safety margin (real life is more between 30% and 65% when expelled from vehicle tank filler neck). Relative speed of expelled volume through the BS surface (not considering gravity) is PS = V/1000/BS = V/1000/ π R 2 Considering gravity (and migration speed of 0.4m/s of vapors, ie: butane worst case), concentration of vapors at bottom side of sphere is C = PS/0.4 C shall be lower than targeted LEL concentration for such zone C = PS /0.4 = V/1000/ π R 2 / 0.4 R = V / (400 π C) Example: if concentration target is 0.1%, R = 40 (l/mn) / 60 (s in a minute) / (400 π ) = 0.67 / (400 x 3.14 x 0.001) R= 0.73 m Safe rounding approach is to convert result to immediate 5 cm superior rounding So 73 cm converts to 75 cm for safe rounding for a sphere with less than 0.1% of vapors outside of it. Example of spheres of zone 0, 1 and 2 and projection to floor ABC1 ABC123 Vehicle being refueled Zoom of filling point interface zoning 11/42

15 For diesel LEL is 0.6%, and saturating pressure is lower than 40 C. Outgoing stream of vapors expelled from the vapor generating point and passing this surface is migrating to the floor at 0.4 m/s (butane light fraction worst case scenario for diesel) Maximum volume of vapors expelled from filler neck is 1% (10hPa / 1013 C) of nozzle flow. For the rest of this assessment, V (volume of vapors expelled) shall be considered as 2% of flowrate of nozzle (safety factor of 2). C shall be lower than targeted LEL concentration for evaluated zone C = PS /0.4 = V/1000/ π R 2 / 0.4 R = V / (400 π C) Example: if concentration target is 0.1%, R = 40 (l/mn) / 60 (s in a minute) * 0.02 / (400 π ) = 0.67 *0,02 / (400 x 3.14 x 0.001) R = / (400 x 3.14 x 0.001) R= m Safe rounding approach is to convert result to immediate 5 cm superior rounding So 10.3 cm converts to 15 cm for safe rounding for a sphere with less than 0.1% of vapors outside of it. 12/42

16 GASOLINE 40 LPM NO VR2 description NH zone When flowrate is 40 liters per minute with a non VR2 nozzle for gasoline (note 1) - interface to vehicle, R 30 cm - interface to vehicle, R 65 cm - Interface to vehicle, R 125 cm - projection to floor of interface sphere R=125 Note: special extra grounding arrangement required between dispenser and boat or aircraft being refueled When flow rate is 40 l/mn or less, it is normal flowrate for cars. All volume of fuel flow is displacing vapors out of the filler neck. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.7% - 1 for any potential concentration above 20% of LEL = 0.14% - 2 for any potential concentration above 5% of LEL = 0.035% R zone 0 = 27.5 cm rounded safe to 30 cm R zone 1 = 61.6 cm rounded safe to 65 cm R zone 2 = 123 cm rounded safe to 125 cm 13/42

17 GASOLINE 40 LPM WITH VR2 description NH zone When flowrate is 40 liters per minute with a VR2 system for gasoline (note 1) - interface to vehicle, R 10 cm - interface to vehicle, R 20 cm - Interface to vehicle, R 30 cm - projection to floor of interface sphere R=30 Note: special extra grounding arrangement required between dispenser and boat or aircraft being refueled When flow rate is 40 l/mn or less, it is normal flowrate for cars. All volume of fuel flow is displacing vapors out of the filler neck, but at least 95% is captured by the VR2 recovery system, so only 40 x 0.05 = 2 liters per minute of vapor can escape in worst case scenario to the external world. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.7% - 1 for any potential concentration above 20% of LEL = 0.14% - 2 for any potential concentration above 5% of LEL = 0.035% R zone 0 = 6.2 cm rounded safe to 10 cm R zone 1 = 13.8 cm rounded safe to 20 cm R zone 2 = 27.5 cm rounded safe to 30 cm 14/42

18 GASOLINE 80 LPM NO VR2 description NH zone When flowrate is > 40 liters per minute and 80 liters per minutes, with a non VR2 nozzle for gasoline (note 1) - interface to vehicle, R 40 cm - interface to vehicle, R 90 cm - Interface to vehicle, R 175 cm - projection to floor of interface sphere R=175 Note: special extra grounding arrangement required between dispenser and vehicle, boat or aircraft being refueled When flow rate is above 40 l/mn and equal or less than 80 l/mn, it is normal flowrate for small trucks or boats. All volume of fuel flow is displacing vapors out of the filler neck. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.7% - 1 for any potential concentration above 20% of LEL = 0.14% - 2 for any potential concentration above 5% of LEL = 0.035% R zone 0 = 38.9 cm rounded safe to 40 cm R zone 1 = 87 cm rounded safe to 90 cm R zone 2 = 174 cm rounded safe to 175 cm 15/42

19 GASOLINE 130 LPM NO VR2 description NH zone When flowrate is > 80 liters per minute and 130 liters per minutes, with a non VR2 nozzle for gasoline (note 1) - interface to vehicle, R 50 cm - interface to vehicle, R 115 cm - Interface to vehicle, R 225 cm - projection to floor of interface sphere R=225 Note: special extra grounding arrangement required between dispenser and vehicle, boat or aircraft being refueled When flow rate is above 80 l/mn and equal or less than 130 l/mn, it is normal flowrate for trucks or boats. All volume of fuel flow is displacing vapors out of the filler neck. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.7% - 1 for any potential concentration above 20% of LEL = 0.14% - 2 for any potential concentration above 5% of LEL = 0.035% R zone 0 = 49.6 cm rounded safe to 50 cm R zone 1 = 111 cm rounded safe to 115 cm R zone 2 = 222 cm rounded safe to 225 cm 16/42

20 GASOLINE 200 LPM NO VR2 description NH zone When flowrate is > 130 liters per minute and 200 liters per minutes, with a non VR2 nozzle for gasoline (note 1) - interface to vehicle, R 65 cm - interface to vehicle, R 140 cm - Interface to vehicle, R 275 cm - projection to floor of interface sphere R=275 Note: special extra grounding arrangement required between dispenser and vehicle, boat or aircraft being refueled When flow rate is above 130 l/mn and equal or less than 200 l/mn, it is normal flowrate for trucks or boats. All volume of fuel flow is displacing vapors out of the filler neck. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.7% - 1 for any potential concentration above 20% of LEL = 0.14% - 2 for any potential concentration above 5% of LEL = 0.035% R zone 0 = 61.6 cm rounded safe to 65 cm R zone 1 = 138 cm rounded safe to 140 cm R zone 2 = 275 cm rounded safe to 275 cm 17/42

21 DIESEL 40 LPM description NH zone When flowrate is 40 liters per minutes, for diesel (note 2) - interface to vehicle, R 5 cm - interface to vehicle, R 10 cm - interface to vehicle, R 20 cm - projection to floor of interface sphere R=20 Note: special extra grounding arrangement required between dispenser and aircraft being refueled When flow rate is 40 l/mn or less, it is normal flowrate for cars. All volume of fuel flow is displacing vapors out of the filler neck. Vapor for diesel is 2% of flow volume. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.6% - 1 for any potential concentration above 20% of LEL = 0.12% - 2 for any potential concentration above 5% of LEL = 0.03% R zone 0 = 4.2 cm rounded safe to 5 cm R zone 1 = 9.4 cm rounded safe to 10 cm R zone 2 = 18.8 cm rounded safe to 20 cm 18/42

22 DIESEL 80 LPM description NH zone When flowrate is > 40 liters per minute and 80 liters per minutes, for diesel (note 2) - interface to vehicle, R 10 cm - interface to vehicle, R 15 cm - interface to vehicle, R 30 cm - projection to floor of interface sphere R=30 Note: special extra grounding arrangement required between dispenser and aircraft being refueled When flow rate is 80 l/mn or less, it is normal flowrate for cars. All volume of fuel flow is displacing vapors out of the filler neck. Vapor for diesel is 2% of flow volume. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.6% - 1 for any potential concentration above 20% of LEL = 0.12% - 2 for any potential concentration above 5% of LEL = 0.03% R zone 0 = 5.9 cm rounded safe to 10 cm R zone 1 = 13.3 cm rounded safe to 15 cm R zone 2 = 26.6 cm rounded safe to 30 cm 19/42

23 DIESEL 200 LPM description NH zone When flowrate is > 80 liters per minute and 200 liters per minutes, for diesel (note 2) - interface to vehicle, R 10 cm - interface to vehicle, R 25 cm - interface to vehicle, R 50 cm - projection to floor of interface sphere R=50 Notes: - special extra grounding arrangement required between dispenser and aircraft being refueled - special extra grounding arrangement recommended between dispenser and vehicle or boat being refueled When flow rate is 200 l/mn or less, it is normal flowrate for cars. All volume of fuel flow is displacing vapors out of the filler neck. Vapor for diesel is 2% of flow volume. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 0.6% - 1 for any potential concentration above 20% of LEL = 0.12% - 2 for any potential concentration above 5% of LEL = 0.03% R zone 0 = 9.4 cm rounded safe to 10 cm R zone 1 = 21 cm rounded safe to 25 cm R zone 2 = 42 cm rounded safe to 45 cm 20/42

24 5) Suggestion for LPG dispensers using EN G Zoning for 1999/92/EC around Recommendation for zoning assessment in application of Directive 1999/92/EC (on minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmosphere) 5.1) General In application of 1999/92/EC directive, temperature class T3 or better is required, and the following zones for gas group IIA, are deemed enough for open air sites using EN certified dispensers: - Idle LPG dispenser: zones defined in EN (see manufacturer s manual) - Installed LPG dispenser: the 5.2 permanent zones are added to the idle dispenser zoning - LPG Dispenser in action: the 5.3 active zones are added to the installed dispenser zoning Note: - Consider boats and aircrafts as vehicle. - Table 2: Known possible configurations in EU countries. Dispensers with flowrates. Only for information Table 2 Flowrate 40 l/mn Most common flowrate for cars (possible use with light trucks, forklifts, boats or light aircrafts) > 40 l/mn 130 l/mn Most common flowrate for trucks, buses heavy work machines, and boats LPG/DME YES YES 21/42

25 5.2) 1999/92/EC recommended PERMANENT zones associated to LPG dispensers description NH zone LPG (or DME) hose reach From dispenser to maximum extend of hose reach, from forecourt floor up to 0,80 meter height Note: 0.8 m is maximum starting height for disable access to payment terminals. DME is Dimethyl Ether. Electronic head of EN certified apparatus above 0.8 meter from forecourt floor (calculator, payment terminal, display) 22/42

26 5.3) 1999/92/EC recommended ACTIVE zones associated to LPG dispensers Dispenser is in action starting from the moment the nozzle is fitted and latched to the vehicle filler neck (start of fill) till the nozzle is disconnected from the vehicle filler neck (end of fill). description NH zone When flowrate is 40 liters per minute - interface to vehicle, R 5 cm - interface to vehicle, R 10 cm - Interface to vehicle, R 20 cm - projection to floor of interface sphere R=20 Note: flow shall be controlled by a dead-man push button, or dispenser attended/used by trained staff. This zoning is to anticipate a small (not visible immediately to operator) leak at nozzle connection with vehicle.. When flowrate is > 40 liters per minute and 130 liters per minutes - interface to vehicle, R 10 cm - interface to vehicle, R 20 cm - Interface to vehicle, R 40 cm - projection to floor of interface sphere R=40 Note: flow shall be controlled by a dead-man push button, or dispenser attended/used by trained staff. This zoning is to anticipate a small (not visible immediately to operator) leak at nozzle connection with vehicle. 23/42

27 Note for all filling stations: Adequate positioning of vehicle/boat/aircraft being refilled will secure active zones away from dispenser and its electronic NH zones. Is deemed adequate any association of one or more of the following steps: proper instructions and signage to end user/driver/pilot paint on forecourt to properly park vehicle or aircraft before fill side stones and/or floor barriers to position vehicle Pillars and/or beams to properly dock boat and limit movement during fill Note for aircraft filling stations: Special care must be taken in considering possible static electricity due to propellers, turbines, air flow around aircraft and length of hose. Grounding sequence of aircraft before fill starts must be carefully understood to avoid any spark at introduction of nozzle spout in tank filler neck. Aircraft must be secured so no unwanted movement will occur during fill. Note for boat filling stations: Special care must be taken in considering possible static electricity due to high speed fill, length of hose and possible movement of boat capable of pulling on nozzle connection with filler neck. Grounding sequence of boat before fill starts must be carefully understood to avoid any spark at introduction of nozzle spout in tank filler neck, or during fill. In this case, special care must be taken to consider surface of water as forecourt level reference for permanent zoning, and secure possible accumulation of vapors under filling deck/pontoon. 24/42

28 5.4) Rationals for zoning scenario for paragraph 5.3 Concept 1: Any leak of LPG from nozzle interface with car will turn to vapors immediately, and these vapors are falling to the floor at around 30 cm/second (worse case Propane). Assumption is LEL is 1.8% for Butane (worse case). EN establishes zone in relation with frequency of exposure. That approach might be fragile when considering petrol stations with public/consumers. CECOD approach is to consider: - 0 for any potential concentration above LEL - 1 for any potential concentration above 20% of LEL - 2 for any potential concentration above 5% of LEL Light vehicle service (flowrate 40 liters per minute) Public Self Service or attended: Leak at nozzle interface is considered as visible if operator is positively attending the fill (dead man push button) and if more than 10 cm 3 or liquid LPG is leaking per minute. If leak is above 10 cm 3 per minute, operator will stop flow by releasing dead-man push button, or activating emergency stop. If leak is 10 cm 3 per minute of liquid LPG, it will generate (worst case scenario) a volume of saturated LPG gas (gaseous form) of - Propane C3h8 = density of liquid at 20 C = cm 3 of liquid creates 10 x / 44 * 22.4 = 2,59 liters of saturated 100% gas - Butane C4H10 = density of liquid at 20 C = cm 3 of liquid creates 10 x / 58 * 22.4 = 2.24 liters of saturated 100% gas Worst case scenario is Propane with 2.59 liters Heavy vehicles (flowrate > 40 liters per minute and 130 liters per minutes) Attended or professional drivers: Leak at nozzle interface is considered as visible if attendant is in close proximity of the fill point and if more than 30 cm 3 or liquid LPG is leaking per minute. If leak is above 30 cm 3 per minute, operator will stop flow by stopping dispenser or activating emergency stop. If leak is 30 cm 3 per minute of liquid LPG, it will generate (worst case scenario) a volume of saturated LPG gas (gaseous form) of - Propane C3h8 = density of liquid at 20 C = cm 3 of liquid creates 30 x / 44 * 22.4 = 7.77 liters of saturated 100% gas - Butane C4H10 = density of liquid at 20 C = cm 3 of liquid creates 3 x / 58 * 22.4 = 6,71 liters of saturated 100% gas Worst case scenario is Propane with 7.77 liters 25/42

29 Concept 2: The speed the LPG vapors are generated creates concentric spheres of hazard (Z0, Z1 and Z2). Such spheres are limited on one side by the vehicle cladding. In zone 2, it is considered that generation speed is not enough to create the upper half of the sphere. Sphere of zone 0 zone around the vapor generating point, where vapors are above LEL during fill. Vapors leaving this sphere shall have a concentration of less than LEL during fill. Sphere of zone 1 zone (excluding zone 0 above) around the vapor generating point, where vapors are above 20% of LEL during fill. Vapors leaving this sphere shall have a concentration of less that 20% of LEL during fill Sphere of zone 2 zone (excluding zone 0 and zone 1 above) around the vapor generating point, where vapors are above 5% of LEL during fill. Vapors leaving this sphere shall have a concentration of less that 5% of LEL during fill. Projection to floor of interface sphere r=xx zone projected from given zone 2 sphere down to the forecourt floor, as zone 2 extends to floor by gravity (vapor heavier than air) Concept 3: Sphere radius calculation a) Even if full sphere is considered as hazardous, only consider ¼ of sphere surface for vapor escape route - ½ because vapors are dropping to the floor, - ½ because dissipation is limited on one side by vehicle cladding b) As a consequence, surface of mix of vapors with air at bottom border of sphere is only 25% of total surface of sphere. Sphere surface is S = 4 π R 2 Bottom border surface of sphere is BS = π R 2 where R is the radius of the sphere in meters, and BS = surface in m 2 of mixing interface surface for vapor with fresh air. Outgoing stream of vapors generated from the vapor generating point and passing this surface is migrating to the floor at 0.3 m/s (propane worst case scenario). 26/42

30 For LPG mixes. LPG liquid turns into vapors at atmospheric pressure. V is the maximum invisible leak. Self service mode with dead man push button - V= 2.59 liters per minute. Attended mode with activation switch V = 7.77 liters per minute. Relative speed of generated volume through the BS surface (not considering gravity) is PS = V/1000/BS = V/1000/ π R 2 Considering gravity (and migration speed of 0.3m/s of propane vapors, worst case scenario), concentration of vapors at bottom side of sphere is C = PS/0.3 C shall be lower than targeted LEL concentration for such zone C = PS /0.3 = V/1000/ π R 2 / 0.3 R = V / (300 π C) Example: if concentration target is 0.1%, R = 2.59 (l/mn) / 60 (s in a minute) / (300 π ) = / (300 x 3.14 x 0.001) R= m Safe rounding approach is to convert result to immediate 5 cm superior rounding So 21.4 cm converts to 25 cm for safe rounding. Example of spheres of zone 0, 1 and 2 and projection to floor ABC1 ABC123 Vehicle being refueled Zoom of filling point interface zoning 27/42

31 description NH zone When flowrate is 40 liters per minute - interface to vehicle, R 5 cm - interface to vehicle, R 10 cm - Interface to vehicle, R 20 cm - projection to floor of interface sphere R=20 Note: flow shall be controlled by a dead-man push button, or dispenser attended/used by trained staff. This zoning is to anticipate a small (not visible immediately to operator) leak leak at nozzle connection with vehicle.. When flow rate is 40 l/mn or less, it is normal flowrate for cars. Maximum non-visible leak at nozzle connection is 10 cm 3 per minutes, creating 2.59 liters of saturated gas in gaseous phase. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 1.8% - 1 for any potential concentration above 20% of LEL = 0.45% - 2 for any potential concentration above 5% of LEL = 0.11% R zone 0 = 5 cm rounded safe to 5 cm R zone 1 = 10 cm rounded safe to 10 cm R zone 2 = 20 cm rounded safe to 20 cm 28/42

32 description NH zone When flowrate is > 40 liters per minute and 130 liters per minutes - interface to vehicle, R 10 cm - interface to vehicle, R 20 cm - Interface to vehicle, R 40 cm - projection to floor of interface sphere R=40 Note: flow shall be controlled by a dead-man push button, or dispenser attended/used by trained staff. This zoning is to anticipate a small (not visible immediately to operator) leak at nozzle connection with vehicle. When flow rate is above 40 l/mn and less than 130 l/mn, it is normal flowrate for heavy vehicles (trucks, buses etc ). Maximum non-visible leak at nozzle connection is 30 cm 3 per minutes, creating 7.77 liters of saturated gas in gaseous phase. Reminder: Targets for zones are - 0 for any potential concentration above LEL = 1.8% - 1 for any potential concentration above 20% of LEL = 0.45% - 2 for any potential concentration above 5% of LEL = 0.11% R zone 0 = 8.7 cm rounded safe to 10 cm R zone 1 = 17.5 cm rounded safe to 20 cm R zone 2 = 35.3 cm rounded safe to 40 cm 29/42

33 6) Suggestion for CNG/LNG (CH 4 ) dispensers (ISO standard pending) Recommendation for zoning assessment in application of Directive 1999/92/EC (on minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmosphere) 6.1) General In application of 1999/92/EC directive, temperature class T2 or better is required, and the following zones for gas group IIA, are deemed enough for open air sites using odorized CH 4 dispenser: - Idle dispenser: zones defined in manufacturers manual - Installed dispenser: the 6.2 permanent zones are added to the idle dispenser zoning - Dispenser in action: the 6.3 active zones are added to the installed dispenser zoning Note: - Consider boats and aircrafts as vehicle. 6.2) 1999/92/EC recommended PERMANENT zones associated to CH 4 dispensers description NH zone CNG/LNG hose reach From dispenser to maximum extend of hose reach, from 2m above forecourt floor up to 4 meters height (dissipation zone) Note: canopy of station shall not have reverse gas traps (as CH 4 in free air ascends by around 80 cm/s) II 3 G certified Electronic head of ISO TC252 project certified apparatus (calculator, payment terminal, display) or Self Power-Off equipment in dispenser head achieved with suitable and adequately positioned gas detector(s) in head 30/42

34 6.3) 1999/92/EC recommended ACTIVE zones associated to CNG/LNG dispensers Dispenser is in action starting from the moment the nozzle is connected to the vehicle filler neck (start of transaction) till: - for CNG : 15 seconds after the nozzle is disconnected from the filler neck of the vehicle (end of flow and dissipation delay for CH 4 ). - for LNG : 120 seconds after the nozzle is disconnected from the filler neck of the vehicle (end of flow and dissipation delay for CH 4 ). (see footnote on this page) description NH zone When flowrate is 20 kg per minute - interface to vehicle or hose breakaway, R 5 cm - interface to vehicle or hose breakaway, R 10 cm - Interface to vehicle or hose breakaway, R 20 cm - projection of interface or breakaway sphere R=20 up to 2 m from floor Note: flow shall be controlled by a dead-man push button, or dispenser attended by trained staff When flowrate is > 20 kg per minute and 60 kg per minutes - interface to vehicle or hose breakaway, R 10 cm - interface to vehicle or hose breakaway, R 15 cm - Interface to vehicle or hose breakaway, R 30 cm - projection of interface or breakaway sphere R=30 up to 2 m from floor Note: flow shall be controlled by a dead-man push button, or dispenser attended by trained staff Note on LNG: LNG gas is very cold (approx -160 C) making density of CH 4 (gaseous form) more than 2 times the usual density of CH 4 at normal ambient temperature. This prevents normal upward dissipation of CH 4 till the gas is capable of warming up to ambient. Such process takes time. Cold CH 4 needs to mix with enough warmer ambient air to warm-up and to start ascending and dissipating. At nozzle disconnection, remaining liquid drops of LNG also need time to evaporate and dissipate. 31/42

35 6.4) Rationals for zoning scenario for paragraph 6.3 Concept 1: G Zoning for 1999/92/EC around Any leak of CNG/LNG from nozzle interface with vehicule or at hose safety breakaway system will dissolve to the atmosphere and start ascending t around 80 cm/second. Assumption is LEL is 5% for Methane. EN establishes zone in relation with frequency of exposure. That approach might be fragile when considering petrol stations with public/consumers. CECOD approach is to consider: - 0 for any potential concentration above LEL - 1 for any potential concentration above 20% of LEL - 2 for any potential concentration above 5% of LEL Light vehicle service (flowrate 20 kg per minute) Public Self Service or attended: Leak at nozzle interface or hose breakway is considered as audible, visible and smells (see note) if operator is positively attending the fill (dead man push button) and if more 100cm 3 (at 1 atm) of gas escape to the atmosphere per second (because of high pressure, this is around 0.4cm 3 of natural gas at 250 bar brutally expending to 100cm 3 at 1 atm with significant noise) Heavy vehicles (flowrate > 20 kg per minute and 60 kg per minutes) Attended: Leak at nozzle interface or hose breakaway is considered as audible, visible and smells (see note) if operator is positively attending the fill (dead man push button) and if more 250cm 3 (at 1 atm) of gas escape to the atmosphere per second (because of high pressure, this is around 1cm 3 of natural gas at 250 bar brutally expending to 250cm 3 at 1 atm with significant noise) Note: Also considering the odorizing compound used in CNG/LNG (Méthanethiol / Mercaptan ) is detectable by nose at levels as low as ppm (ref: INRS-France FT190 edition 2007) and heavier than air, so smell of a leak remains longer than leak itself, and is nose detectable. 32/42

36 Concept 2: The speed Methane/CNG/LNG is ejected creates concentric spheres of hazard (Z0, Z1 and Z2). Such spheres are limited on one side by the vehicle cladding. In zone 2, it is considered that generation speed is not enough to create the lower half of the sphere. Sphere of zone 0 zone around the leak point, where methane concentration is above LEL during fill. Gas/air mix leaving this sphere shall have a concentration of less than LEL during fill. Sphere of zone 1 zone (excluding zone 0 above) around the leak point, where methane concentration is above 20% of LEL during fill. Gas/air mix leaving this sphere shall have a concentration of less that 20% of LEL during fill Sphere of zone 2 zone (excluding zone 0 above) around the leak point, where methane concentration is above 5% of LEL during fill. Gas/air mix leaving this sphere shall have a concentration of less that 5% of LEL during fill Concept 3: Sphere radius calculation a) Even if full sphere is considered as hazardous, only consider ¼ of sphere surface for gas/air mix escape route - ½ because methane is going up at 80 cm/s, - ½ because dissipation is limited on one side by vehicle cladding b) As a consequence, surface of mix of methane with air at upper border of sphere is only 25% of total surface of sphere. Sphere surface is S = 4 π R 2 Upper border surface of sphere is BS = π R 2 where R is the radius of the sphere in meters, and BS = surface in m 2 of mixing interface surface for methane with fresh air. Outgoing stream of methane generated from the leak point and passing this surface is migrating up at 0.8 m/s. Ascending speed information Thanks to: Association Suisse de l Industrie Gazière - Verband der Schweizerischen Gasindustrie essiggas_d.pdf Note: Small leaks with LNG will also ascend after a few seconds, as dissolution inside sphere of Z2 brings enough calories from ambient air to warm up CH 4 to ascending densities. 33/42

37 For CNG/LNG. V is the maximum invisible leak (gas at 1 atm). Safety factor is 2. Relative speed of generated volume through the BS surface (not considering gravity) is PS = V/1000/BS = V/1000/ π R 2 Considering gravity (and migration speed of 0.8m/s of methane), concentration of CH4 at top side of sphere is C = PS/0.8 C shall be lower than targeted LEL concentration for such zone C = PS /0.8 = V/1000/ π R 2 / 0.8 R = V / (800 π C) Example: if concentration target is 0.1%, R = 0,1 (100cm3 per second) x 2 (safety) / (800 π ) = 0.2 / (800 x 3.14 x 0.001) R= m Safe rounding approach is to convert result to immediate 5 cm superior rounding So 28,2 cm converts to 30 cm for safe rounding. Example of spheres of zone 0, 1 and 2 Z2=Up to 2m ABC1 ABC123 Vehicle being refueled Zoom of filling point interface zoning 34/42

38 description NH zone When flowrate is 20 kg per minute - interface to vehicle or hose breakaway, R 5 cm - interface to vehicle or hose breakaway, R 10 cm - Interface to vehicle or hose breakaway, R 20 cm - projection of interface or breakaway sphere R=20 up to 2 m from floor Note: flow shall be controlled by a dead-man push button, or dispenser attended by trained staff When flowrate is > 20 kg per minute and 60 kg per minutes - interface to vehicle or hose breakaway, R 10 cm - interface to vehicle or hose breakaway, R 15 cm - Interface to vehicle or hose breakaway, R 30 cm - projection of interface or breakaway sphere R=30 up to 2 m from floor Note: flow shall be controlled by a dead-man push button, or dispenser attended by trained staff When flow rate is 20 kg per minute, it is normal flowrate for cars and small trucks. Maximum non-visible leak at nozzle connection is 100 cm 3 per second (1 atm). Safety factor for this assessment is 2 Reminder: Targets for zones are - 0 for any potential concentration above LEL = 5% - 1 for any potential concentration above 20% of LEL = 1% - 2 for any potential concentration above 5% of LEL = 0,25% R zone 0 = 3.99 cm rounded safe to 5 cm R zone 1 = 8,92 cm rounded safe to 10 cm R zone 2 = 17,8 cm rounded safe to 20 cm When flow rate is 60 kg per minute, it is normal flowrate for trucks and buses. Maximum non-visible leak at nozzle connection is 250 cm 3 per second (1 atm). Safety factor for this assessment is 2 R zone 0 = 6,3 cm rounded safe to 10 cm R zone 1 = 14,1 cm rounded safe to 15 cm R zone 2 = 28,2 cm rounded safe to 30 cm 35/42

39 7) Suggestion for H 2 dispensers G Zoning for 1999/92/EC around Recommendation for zoning assessment in application of Directive 1999/92/EC (on minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmosphere) 7.1) General In application of 1999/92/EC directive, temperature class T1 or better is required, and the following zones for gas group IIC, are deemed enough for open air sites using H 2 dispenser: - Idle dispenser: zones defined in manufacturers manual - Installed dispenser: the 7.2 permanent zones are added to the idle dispenser zoning - Dispenser in action: the 7.3 active zones are added to the installed dispenser zoning Note: - Consider boats and aircrafts as vehicle. 7.2) 1999/92/EC recommended PERMANENT zones associated to H 2 dispensers description NH zone H 2 hose reach From dispenser to maximum extend of hose reach, from 2m above forecourt floor up to 4 meters height (dissipation zone) Note: canopy of station shall not have reverse gas traps (as H 2 in free air ascends by around 100 cm/s) II 3 G certified Electronic head of certified apparatus (calculator, payment terminal, display) or Self Power-Off equipment in dispenser head achieved with suitable and adequately positioned gas detector(s) in head 36/42

40 7.3) 1999/92/EC recommended ACTIVE zones associated to H 2 dispensers Dispenser is in action starting from the moment the nozzle is connected to the vehicle filler neck (start of transaction) till 15 seconds after the nozzle is disconnected from the filler neck of the vehicle (end of flow and dissipation delay for H 2 ). description NH zone When flowrate is 10 kg per minute - interface to vehicle or hose breakaway, R 10 cm - interface to vehicle or hose breakaway, R 15 cm - Interface to vehicle or hose breakaway, R 30 cm - projection of interface or breakaway sphere R=30 up to 2 m from floor Note: flow shall be controlled by a dead-man push button, or dispenser attended by trained staff When flowrate is > 10 kg per minute and 40 kg per minutes - interface to vehicle or hose breakaway, R 10 cm - interface to vehicle or hose breakaway, R 25 cm - Interface to vehicle or hose breakaway, R 45 cm - projection of interface or breakaway sphere R=45 up to 2 m from floor Note: flow shall be controlled by a dead-man push button, or dispenser attended by trained staff 37/42

41 7.4) Rationals for zoning scenario for paragraph 7.3 Concept 1: G Zoning for 1999/92/EC around Any leak of H 2 from nozzle interface with car or at hose breakaway system will dissolve to the atmosphere and start ascending t around 100 cm/second. Assumption is LEL is 4% for hydrogen. EN establishes zone in relation with frequency of exposure. That approach might be fragile when considering petrol stations with public/consumers. CECOD approach is to consider: - 0 for any potential concentration above LEL - 1 for any potential concentration above 20% of LEL - 2 for any potential concentration above 5% of LEL Light vehicle service (flowrate 10 kg per minute) Public Self Service or attended: Leak at nozzle interface or hose breakaway is considered as audible and visible if operator is positively attending the fill (dead man push button) and if more 100cm 3 (at 1 atm) of gas escape to the atmosphere per second (because of high pressure, this is around 0.25cm 3 of hydrogen at 400 bar brutally expending to 100cm 3 at 1 atm with significant noise) Heavy vehicles (flowrate > 10 kg per minute and 40 kg per minutes) Attended: Leak at nozzle interface or hose breakaway is considered as audible and visible if operator is positively attending the fill (dead man push button) and if more 250cm 3 (at 1 atm) of gas escape to the atmosphere per second (because of high pressure, this is around 0,6 cm 3 of hydrogen at 400 bar brutally expending to 250cm 3 at 1 atm with significant noise) 38/42