Are you interested in the station installation guidelines for LPG? Learn about the basics guidelines, processes, and experiences of installing a LPG station.

1. Installation Guidance :
LPG (Autogas) Refueling
Stations
Gas Technology Institute
March 2014

2. Objectives
A. LPG Fuel
B. Fueling Basics
C. Codes and Standards
D. Station Basics
E. Equipment Location
F. Electrical Hazardous Area Classification
G. Station Installation
H. Fire Protection
2

3. LPG Fuel
o LPG or Propane has the chemical formula C3H8
o Propane is produced when natural gas is processed
and crude oil is refined.
o It is nontoxic, colorless, and odorless (odorant is
typically added for detection)
o At atmospheric pressure and ambient temperatures
Propane exists in a vapor form
o Like gasoline or diesel, Propane gas is heavier than air
o Propane is a NFPA Class IA flammable liquid
3

4. Fueling Basics
oThe service pressure of a propane fuel system is
at least 240 psig. At this pressure the LPG will
stay a liquid at temperatures of 120° F or less
o By code, LPG fuel tanks are only allowed to be
filled to roughly 80% of volume
o Fueling is either stopped by a auto stop fill valve
installed in the fuel system or manually stopped
by operator by observing level gauge and bleed
valve vent
4

5. Codes and Standards
Accepted Codes:
oNFPA 58: Liquefied Petroleum Gas Code 2011
oNFPA 70: National Electric Code (NEC) 2011:
Article 500: Hazardous (Classified) Locations,
Article 501: Class 1 Div.1 & 2 Hazardous Locations
oNFPA 30A: Code for Motor Fuel Dispensing
Facilities and Repair Garages 2012 (Addresses
additional requirements when LPG fueling is
added to an existing liquid petroleum fuel station)
oInternational Fire Code (IFC): Chap 22 is not
recognized in Wisconsin
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6. Station Basics
o ASME Storage Tank: Rated Design Pressures per NFPA 58:
5.2.4.2
o Pump, Metering Devices, and Dispensers (Listed): Rated
for Hazardous Locations
o Card Reader System or Fuel Management System to
authorize transactions
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7. Station Basics
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8. Station Basics
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9. Equipment Location
NFPA 58 Chapter 6 & NFPA 30A Chapter 12 address
equipment placement and set backs
o Pumps, Storage, and Dispensing Equipment are addressed
o Location, either indoors (NFPA 58 Chap10 applies) and
outdoors, of the equipment matters
o In some instances a combination of both codes will give
guides on final equipment placement e.g. tank separation
(from other aboveground fuel tanks & dispenser)
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10. Equipment Location
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11. Electrical Hazardous Area Location
NFPA 58 & NFPA 30A establish electrical area
classification for outdoor stationary Propane fueling
stations
o Pressure Relief Points, aboveground storage tanks,
remote mounted pumps, dispensers, and points of
transfer are discussed in Chapter 6 of NFPA 58
Electrical Conduits and Wiring must be installed per
approved methods indicated in NEC for classified areas
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12. Electrical Hazardous Area Location
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13. Station Installation - Aboveground
Tanks
o Aboveground horizontal ASME tanks are supported by
structural steel saddles and slotted and designed to allow
for expansion and contraction
o Horizontal ASME tanks are required to be installed on
masonry or other noncombustible supports located on
concrete or masonry foundations
o For containers 2000 gal. or less the pump can be
mounted on a common base assuming bottom of
container meets dimensions
o Tanks are to be physically protected
13

14. Station Installation - Piping
o Piping sizes range from ¾” to 2” depending on
dispenser design
o Metallic piping and fittings are to be fabricated,
installed, and tested per ASME B31.3, Process
Piping Code
o Pressure Ratings defined in NFPA 58: 6.9.3.3
oMetallic pipe joints are permitted to be threaded,
flanged, welded, or brazed
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15. Station Installation - Piping
oPiping systems should be routed in a practical
manner from point to point
oMinimum cover depth is 12”, this is increased to
18” if there is potential for external damage
oBuried metal pipe must be protected against
corrosion
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16. Station Installation - Dispenser
oThe dispenser should be a listed device NFPA
30A: 6.3.2
oDispenser installed under a canopy, the area shall
be ventilated and have at least 50% of perimeter
open to outdoors
oProtection against trespassing and tampering
should be installed
oDispenser should be installed on a concrete
foundation or apart of a complete storage and
dispensing unit mounted on the same base
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17. Station Installation- Dispenser Cont.
o Hose length is not to exceed 18 ft., listed, and
protected from damage if not used
o Listed breakaway device per ANSI/UL 567
o Identified and accessible switch or circuit breaker
should be installed within 20 -100 ft. of dispenser.
Markings for the switch should be made visible at
point of transfer
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18. Station Installation- Misc.
o An excess flow valve or differential back pressure valve
should be installed where LPG hose is connected to liquid
piping
o Hydrostatic relief valves installed between isolating shutoff
valves
o The LPG tank opening should be equipped with either 1)
internal valve fitted for remote closure and automatic shutoff
using thermal actuation or 2) a positive shutoff valve located
as close to the tank as possible in conjunction with an
excess flow valve and a remotely actuated emergency
shutoff valve
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19. Station Installation- Misc.
o An emergency shutoff device (switch, button, lever, etc.)
shall be required within 3 -100 ft. from the liquid transfer
point
o Actuated emergency shutoff and internal valves should be
tested annually
o Manual shutoff valve and excess flow valve shall be
located in liquid line between pump and dispenser when
dispenser is remote to pump/storage location
o Typically safety devices/features are included in the
equipment and/or station design
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20. Station Installation- Shutdown and
Safety Device Schematic
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21. Fire Protection
o Fire Protection is required for installations with an
aggregate water capacity greater than 4000 gal.
o If required, a Fire Safety Analysis shall be submitted to the
AHJ by owner operator of the station.
o NFPA publishes the “Fire Safety Analysis Manual for LPGas Storage Facilities” providing guidance in completing
an analysis in conjunction with NFPA 58 requirements.
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22. References
o AFDC’s Propane Fuels and Vehicles sections (www.afdc.
energy.gov)
o Local Clean Cities coordinator (www.cleancities.energy.
gov)
o Propane Education & Research Council
(www.autogasusa.org ; www.propanecouncil.org)
o National Propane Gas Association (www.npga.org)
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23. Acknowledgement of Support
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24. Questions?
Thank you for your time.
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25. Autogas 101
J. Sells – Director Autogas – 904-545-9743
j.sells@amerigas.com
David Rigney – National Account Manager (West-South) – 386-299-9442
david.rigney@amerigas.com
Chris Ransom – National Account Manager (East-Central) – 231-638-3184
chris.ransom@amerigas.com

26. Propane Autogas
• Clean burning
• Readily available
• Most widely used alternative motor fuel in the world
• 3rd most commonly used motor fuel
• Powers approx 270,000 vehicles in the US
• Only alternative fuel with existing fueling stations in every
state

27. DOMESTICALLY PRODUCED
Around 97% of propane
autogas is produced here in
the U.S., reducing our
dependence on foreign oil and
increasing American energy
security.

28. Propane Autogas Pricing
• Relative to Gasoline/Diesel
• 9/24/2013 – LPG $1.89, Gasoline Reg. unleaded $3.59,
Diesel $4.10
• Relative to Propane for home, commercial, cylinder gas
applications
• –Priced differently
• –Awareness of retailer pricing propane as autogas vs.
cylinder gas
• Winter Spike – supply and demand
• Limited # of distributors in market
• Propane Autogas priced with excise taxes
• Currently $.50 per gallon tax credit

29. Propane Autogas Refueling Infrastructure

30. Fleet Users
•Autogas
station installed on-site at fleet base
•Spill-free dispenser with familiar design
•Fully scalable to serve fleets of all sizes
•Works well with fuel management systems
•All necessary training for fleet personnel
•Installation time –as fast as 1-2 days
Example:
1,000 gallon tank/pump/meter/hose/nozzle/cabinet
30,000 gallon tank, pump, dispenser, systems integration
Infrastructure installation requires fuel consumption
(difficult to consider installing infrastructure for a fleet with
only a few vehicles)

31. Electronic Autogas Refueling Station

32. Infrastructure Cost Factors
•
•
•
•
•
•
•
•
•
Tank and support costs
Lines and installation
Pump
Dispensing mechanism
o Basic electronic to full service including software
integration, card readers, fuel management, printers,
etc.
Electrical Supply –single phase or three phase current
Impact Protection
Cost of autogas refueling infrastructure is significantly
lower than other alternatives
Mobile – easily relocated
Refueling stations may be installed at no cost in exchange
for a fuel contract

33. Support/ Maintenance
•
Provide regular interval training and system
inspections
•
Minimal Response Time
•
•
Alternative Fueling Options
–Mobile Refueling
–Retailers
–Dual Fuel Systems
Minimal to zero lost time

34. Vehicle Conversions
• Bi-Fuel Conversions systems
–EPA Emissions Certifications – time/cost
–Cost effective – rapid ROI for certain vehicles
($5500-$7200)
–Operating Range significantly increased
–Transferable to other certified engines
–Warranty
–Technology advancements vs. consumer
beliefs

35. Vehicle Conversions
OEM/Dedicated
–EPA Emissions Certifications
–Cost difference – ($10,000-$12,000)
–Factory Warranty
–Limited Manufacturers in the market
currently – number is growing
–Dedicated Fuel – requires home base
fueling in many circumstances

36. Vehicle Maintenance
• Increased time between maintenance
intervals
• No modification required to shops
• Efficient training/certification process for
maintenance and refueling

37. Safety
Myths regarding propane vehicles vs. other
fueled vehicles
–Storage tanks
–Emergency valves
–Risk of ignition compared to gasoline

38. Public Refueling
• AFDC website is an excellent source for
propane motor fuel stations
• Public Stations with appropriate pricing is
limited but growing
• Reminder – awareness of how retailer is
pricing propane autogas
• Current Code Limitations

39. Consumer Education and Awareness
• Need Increased vehicles on the road
• Inform consumers regarding safety
• Educate consumers on the economics
• Educate consumers on the benefits to US

40. Questions?