GUIDELINES & DOC No: OMC/SP/CNG/31

STANDARD OPERATING Eff. Date : 01-12-2015.

PROCEDURE (SOP)

AT CNG RETAILOUTLET

“ DRIVING THE QUEST FOR A CLEAN , GREEN &

SAFE FUTURE USING COMPRESSED NATURAL GAS”

GUIDELINES
AND
STANDARD OPERATING PROCEDURES

FOR CNG HANDLING

AT

RETAIL OUTLET

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A TYPICAL CNG STATION AT OMC RETAIL OUTLET

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Contents. Page.
1.0 Purpose for Guidelines & CNG SOP : 4

2.0 Roles & Responsibilities for operation of CNG RO : 4

3.0 CNG Retail Outlet –Activities & Roles : 5- 8

4.0 Standard Operating Procedure (SOP) : 9

4.1 SOP for CNG Re-fuelling at RO : 9

4.2 SOP for CNG Attendants-Pre-Checks of CNG vehicle: 10-12

5.0 Information Display for CNG customers RO : 12-13

6.0 Daily checks for Dealers at CNG RO : 13

7.0 Emergency response system (Display) : 14

8.0 DOs & DON’Ts for safe CNG filling by dealers/attendants(Display) :

8.1 DOs : 15-17

8.2 DON’Ts : 17-19

9.0 Critical information of CNG fuelling Equipments : 19-24

9.1 Specifications of CNG Cylinder : 19

9.2 Mounting of cylinder : 19

9.3 CNG Dispensing unit : Types & safety features 20

9.4 Emergency Isolation Valve ; 21

9.5 Break way Coupling at DU : 22

9.6 Emergency Shut off Device (ESD): 23

9.7 Pressure Gauge at DU : 24

Annexure– I : Daily checklist to be filled by dealer at CNG RO: 25-26

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1.0 PURPOSE :
The purpose of this Guidelines is to provide Standard Operational Procedure and
steps for handling CNG fuelling at OMC Retail Outlets by RO Dealers & their
Attendants to ensure that :

 Dispensing of CNG in to vehicles is done in a safe manner with minimum checks

required in the vehicles by the vehicle owner & CNG Dispensing Attendants.

 Ensure a reliability of services through un-interrupted supply of CNG to various

Dispensing units.

 All Legal & statutory obligations are properly followed by all concerned.

 There is no loss of life & property from fire and explosion or traffic accident.

2.0 ROLES AND RESPONSIBILITIES FOR OPERATION OF CNG RO :

The role and Responsibility shall be as per the term of the CNG Standard Agreement signed
between OMC & concerned CGD Co and RO Dealership Agreement signed between OMC and
RO dealer.
This Standard Operating Procedure covers

a). Standard Stepwise Procedure for handling & fuelling CNG vehicles at Retail Outlets.

b). Checklists for CNG RO dealers.

The procedure described here under is for internal control, monitoring and clarity on step by
step standard Operation of CNG Fuelling and also ensuring Maintenance & Safety activities
routinely under taken at CNG Station.

The Standard Operating Procedure (SOP) is not to supersede the CNG Agreement signed between
OMC & CGD Cos and also the Dealership Agreement signed between OMC & RO Dealer , but
to support the same.

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3.0 CNG RETAIL OUTLET -- ACTIVITIES AND ROLES :

S.No. Activity Steps To be done
by

3.1.0 MANDATORY REQUIREMENT AT CNG RO :

3.1.1 Daily visit to all parts of the CNG Station premises prior to start to identify By CGD
hazards and actions are to be taken , if required. All the Fire fighting systems Co
within the battery limit of CNG compressor/cascade premises to be available &
functional as per PESO rules , Fire Department’s requirements and approved
drawings

3.1.2 To ensure that all the Fire fighting equipment in fore court area are available & RO
functional as per PESO rules , Fire Department’s requirements and approved Dealer/CO
drawings. CO
operator .
3.1.3 All incident/accident/near miss observed to be brought to the notice of CGD co
authorised CGD Co representative & OMC rep. rep & RO
dealer

3.2.0 CNG COMPRESSORS – OPERATING ACTIVITIES & ROLES :

3.2.1 Availability of an updated contact address & mob nos. of operators scheduled By CGD co
for duty at CNG RO . control
centre

3.2.2 Handing over/taking over of duty of their respective shift by CGD operator ensuring By CGD
assessment of the general conditions of the system by going through the Log book and Co. rep
plan specific activities if any, during his shift.

3.2.3 Monitoring of specific operating parameters of compressors & the Engine periodically
as per CGD guidelines .Abnormalities ( operating parameters like stage pressure &
temperature , oil pressure, etc.) if any, to be recorded and communicated to Control By CGD Co.
centre/Maintenance Team of CGD Co rep

3.2.4 To go through the logbook maintained by the Compressor Operator , get the stock of RO Dealer .
situation and act accordingly .Ensure that Do’s & Don’ts (Annexure-1) are followed by
CNG attendants.

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3.2.5 In case of power supply failure , co-ordination with electricity company till restoration RO Dealer.
of supply.

3.2.6 Decision to shut down the CNG Stations , some of the situations being as below: By CGD Co
 Compressor not running and no alternative available . in
 CNG dispensers not working . consultatio
n with
 Any failure e.g. dispensing Gas quantity not getting registered etc. OMC Rep.
 Violation of CNG filling Practices .

 Statutory Licence (PESO Licence / W&M Certificate) expired.

 Any litigation requiring closure.

Any untoward incident within or around premises endangering Safety.

3.2.7 Analyse Reports related to Compressor delivered capacity , power and Lubricating Oil By CGD Co.
consumption for each Compressor and based on findings , necessary action taken.

3.3.0 MOBILE CASCADE HANDLING - ACTIVITIES & ROLES:

Parking of mobile Cascades received from CNG Mother Station at designated location at RO Dealer
the CNG RO premises. Direction to the drivers for parking the vehicle ensuring the
vehicle is parked safely .
3.3.1 To ensure that the flexible tube passes through the key ring of the ignition key before By CGD Co.
attaching the same with the point provided for filling the cascade. In no circumstances Rep
, the key to be kept at any other locations.
3.3.2 Connecting and the flexible tube connection from the mobile cascade vehicle at CGD Co
Daughter Station for filling the stationery Cascades & disconnection . Rep.

3.3.3 Coordination with CNG Control Office of CGD Co to ensure continued supply of CNG RO Dealer
supply at CNG Station .

3.4.0 CNG DISPENSER - OPERATING ACTIVITIES & PROCEDURES : Action By

3.4.1 Proper positioning of vehicle near the dispenser for safe dispensing avoiding RO Dealer
misalignment .Ensuring Occupants of the vehicle are alighted & moved to a safe place.
3.4.2 To ensure that the customer has checked the Zero reading of the dispenser prior to RO Dealer
start of CNG filling process.
3.4.3 Checking of CNG cylinder hydro test compliance validity by checking the metal plate on
the body of the cylinder or on the vehicle prior to commencement of filling.(Vehicle
owners to ensure that CNG vehicle’s Cylinder is hydro tested every three years and RO Dealer.
revalidated from authorised test centres for safe CNG filling .

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3.4.4 To carry out daily check maintain records as per Check List for verification by OMC RO Dealer
Representative
3.4.5 To stop filling in case of any leakage from CNG KITs installed in the vehicle is observed RO Dealer
at the RO site and the customer to be advised to take his/her vehicle in a safe area.
The Dispensing in the vehicle to be resumed only after ensuring that the leakage has
been completely arrested.
3.4.6 Check for condition of the dispenser probe ‘O’ rings & replace , if required RO Dealer
in
consultatio
n with CGD
Co. Rep.

3.4.7 To prominently display its operating Procedures & safety Signage at CNG RO premise CGD co to
to educate /aware the customers . display
&RO dealer
to
maintain.
3.4.8 To Ensure that :
 Un-authorised Entry & Trespasser are not be allowed in Fenced /demarcated
area of Compressor/Cascade premises. RO Dealer
 Operation & Maintenance of CNG equipments to be carried out by trained
Personnel/Contractors /Rep of CGD Co only as per work permit /clearance CGD Co .
issued by CGD Co
 CNG Filling Operation is carried out by trained CNG Dispensing Attendant. RO dealer.

3.4.9 Training of DSM/Dispensing Attendant & issuance of Training Certificate and also RO Dealer
Renew the training Certificate prior to expiry. & CGD CGD
CGD Co Representative is to intimate about their Training schedule . co.

OMC RO Dealer is to ensure that Dispensing Attendants are deputed for attending RO dealer
the Training workshop.

3.5.0 STANDARD MAINTENANCE ACTIVITIES & ROLES :

3.5.1 Preparation of Annual Maintenance Schedule by CGD Co taking into consideration the CGD Co
recommendation made in equipment supplier’s manual & History card . To carry out
maintenance as per schedule.
3.5.2 Routine checks as per the task list of CGD co. to be carried out & records maintained. CGD Co

3.5.3 Preventive Maintenance Activities as per the task list of CGD co. & carried out issuing CGD Co
work permit and records maintained.

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3.5.4 Updation of History Cards by CGD Co. & review of the same CGD Co

3.5.5 Prior to start up of any Preventive /Routine & Break down Maintenance at the CNG CGD Co
Station, CGD Co Rep to inform RO Dealer for taking all safety precautions in the
CNG premises & display a copy of the work permit for information of all concerned. &
Dealer to ensure all safety precautions in the CNG premises as advised by CGD co. RO Dealer.
representative during the Maintenance work being carried out by CGD Co
representative.

3.5.6 DISPENSER MAINTENANCE ACTIVITIES & ROLES : CGD Co .

To carry out routine, Preventive & Breakdown Maintenance of CNG Dispensers by CGD rep
Co as per their scheduled task list & norms & records maintained. Dealer to ensure
all safety precautions in the CNG premises as advised by CGD co. representative .

3.5.7 UTILITIES’ MAINTENANCE ACTIVITIES : CGD Co.

rep
Maintenance of Compressor utilities like UPS /LT Panel by CGD Co , as per their
supplier’s manual recommendations. Updation of History Card of these equipments.
3.6.0 WORK PERMIT ISSUANCE :

3.6.1 Issue of work permit prior to start of any Preventive and Regular Maintenance of CNG CGD Co.
Equipments at CNG RO to its authorised Representative / Service Engineer/Contractor.

3.6.2 To ensure that any maintenance work is being carried out at the RO by CGD Co’s RO Dealer
Representative with a valid Work Permit issued by CGD Co . , else to be reported to
Head-CNG /CNG Control Room of the CGD Co under intimation to OMC .

3.7.0 CALIBRATION OF CNG EQUIPMENTS : CGD Co.

Calibration of all the measuring equipments as per their laid down frequency and also
as per statutory requirement & records maintained. RO delaer
Maintenance of weights & measures calibration certificates

3.8.0 COMPLIANCE ACTIVITIES ON STATUTORY ISSUES :

To ensure that all the licenses /NOC from competent authority are prominently RO Dealer
displayed at the CNG RO premises by RO Dealer .
OMC

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4.0 STANDARD OPERATING PROCEDURES (SOP) :

4.1 SOP FOR CNG RE-FUELLING AT RO :
Steps / by CNG Filling Attendant
Procedure
1 Park the vehicle at a convenient place near CNG Dispenser .
2 Make sure all occupants of the vehicle alight and move away to a safe area
3 Turn off the vehicle Ignition & ensure no sources of Ignition
4 Make sure vehicle is in gear while parked or Hand brakes applied.
5 Ensure that the compliance plate is available on the cylinder or on the
vehicle. Check the validity of Hydro Testing Due Date of CNG filling cylinder
by checking the plate and/ or relevant documents. If any shortcoming /
damage is found, customer should be advised to get it rectified before
Dispensing of CNG.
7 Open the CNG filling point on the vehicle cylinder by removing the cap/ dust
plug after opening the bonnet or side cover as the case may be.
8 Place rubber mat on battery terminals, if the filling point is under the
bonnet .
9 Insert filling probe/NGV nozzle in to receptacle and check for proper
connection.
10 Ensure "zero" register on Dispenser Display & show it to customer.
11 Open the 3-Way Valve/Nozzle Handle for gas to flow from hose to cylinder.
12 Press “ON “switches on dispenser to start the gas filling into cylinder. (Gas
flow from dispenser to cylinder stops automatically once filling is
completed).
13 After completion of Gas filling of the vehicle, ensure to turn the 3-Way
Valve , first in Close position and then in Vent position , allowing to slowly
vent the gas, trapped in the probe and Hose, to atmosphere.
14 Remove the filling hose from cylinder & keep it properly on hostler and put
back the cap/ dust plug on the filling point.
15 Remove the insulating mat from battery terminal & drop the bonnet or shut
the side cover
16 The Fore Court Attendant to guide the vehicle out of filling point & slowly
move out of place .

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4.2 SOP FOR ATTENDANTS : PRE-CHECKS OF VEHICLES

BEFORE CNG REFULEING :

 Dealer /Attendant to check the following details on the “Metal Plate”

of the Vehicle Cylinder for quick verification of suitability of vehicle
for CNG filling :
 Vehicle Registration No.
 Date of last Hydro Test.
 Due Date of Next Hydro test (due in every three years as per
PESO rules ).

 That , there is no presence of any live material that can cause fire. e.g.
open ended electrical wires, any type of sparking etc, particularly in
battery unit.
 that there is no ignition source or inflammable material inside the
vehicle before the vehicle enters in to Dispensing Area. ( e.g.
Agarbattis , match box, cigarette etc.)
 that there is no Passenger inside the vehicle before it enters in to
CNG Dispensing Area
 Mobile Phone not to be allowed inside the Dispensing Area.

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 that , the lights, car deck and electrical / battery operated items
should be switched off completely in the Vehicle.
 That , the Marshalling for Proper parking of the Vehicle in the CNG
Dispensing area & Parking Brake has been applied before fuelling.
 that , the Engine of the Vehicle is Switched Off before fuelling.
 Attendant to assist the Vehicle Owner in opening of the Bonnet for
fuelling .
 Demonstration of Attendants for Leakage Check of CNG Vehicles
with Soap solution :

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5.0 IMPORTANT INFORMATION FOR CNG CUSTOMERS AT RO

 Get down from the vehicle at the entry of CNG station.
 switch off mobile phone before entering the CNG stations area. Use of
mobile phone is strictly prohibited in CNG station area.
 Vehicle engine to be turned off and hand over the key to CNG filling
attendant before CNG filling.
 No persons (driver and passengers) allowed to be inside the vehicle before
CNG filling.
 Do not use match box, open flame in CNG area. Smoking is strictly
prohibited.
 Driver/customer of the vehicle to ensure each CNG Cylinder carry the
following details on a “Metal Plate” for quick verification at the RO .
 Vehicle Registration no.
 Date of last Hydro Test
 Due Date of next Hydro test
 These cylinders to be subjected to hydraulic test at least once in every three
years authorized test centres
 Terminals of battery to be covered with caps/ dust plugs.
 Do not get panic in case of Emergency & Stay Away from the emergency
area.
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 In case of leakage of CNG, do not start the vehicle and push the vehicle to
an isolated place and immediately shut off the cylinder valve.

 Do not spread rumours in case of emergency & follow the instructions of

CNG station Staffs .

 Always obey Security & Safety guidelines in CNG station.

6.0 DAILY CHECKS FOR DEALER AT CNG STATION :

• Daily check list as per Annexure I to be filled in by the dealer and records
maintained.
• To check that CNG DU Attendant & CGD Operator wear PPEs e.g. Shoes
, helmet etc.

• All approaches to machines / compressors, storage cascade and work place

are free from obstacles so that they are readily accessible in case of any
emergency.
• The valid STC - Card ( Safety & Technical Competence ) , issued by CGD
Co. is to be displayed by DU Attendant on his body.
• To Check for proper functioning of Emergency Shutdown device (ESD) of
each dispensing unit before refueling of CNG .

• That there is no leakage in refueling assembly during refueling .

• that their is no external damage, bulging, cut marks and abrasion to the
flexible hoses.

• Good condition of refueling Probe.

• No Mobile phone usage inside the CNG Station .

• Proper arrangement for marshalling of the customers vehicle and display of

Sign board for entry/exit at CNG refueling Station.
• To ensure No Smoking / No naked flame / No Spark in CNG premises

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 Leaking vehicle, if observed, is pushed manually to a safe place

without starting the engine.
 Ensure that two valid DCP type Fire Extinguishers of 9/ 10Kgs each
are available in CNG Dispensing area always.
7.0 EMERGENCY RESPONSE TEAM ORGANISATION CHART : < To D
ISPLAY>

HSE Coordinator
Mr. :
Zonal/Regional/State Head Phone :
Mr :
Phone : CC & PR Coordinator
Mr. :
Phone :
DM/TM/RM:
Mr.
Phone: Legal Coordinator
Mr. :
Phone :
Field Officer
Site Incident Controller (SIC) PESO Office
Mr : Phone :
CGD Co. Control
Room
Phone : RO Dealer (coordinator) Fire Brigade
CNG Head, CGD Mr : Phone No. :
Co.
Police Station

EMERGENCY INCIDENT
Name of RO :
Location :
CGD Co. Name :

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8.0 Do’s and Don’ts for CNG filling by RO Dealer & Attendants:

8.1 Do’s :
1. On gas leakage , immediately close / isolate the cylinder shutoff valve,
open the doors of the vehicle and park it in open space;
2. Always put on the dust plug / cap back on to the vehicle filler valve
after filling of vehicle;
3. Always disconnect the electrical power supply and vent gas before
servicing the filter;
4. CNG should be slowly introduced into the vehicle / cylinder to avoid
shock loading and a rapid increase in gas temperature;
5. Visual inspection of the hoses assembly should be done every week;
6. Clean all the parts of the dispensers to avoid chocking up / corrosion;
7. The nozzle jaws to be checked daily for wear and replaced as needed;
8. Stand at a safe distance during refilling;
9. Keep records for all the refused refuelling vehicles with reasons for
refusing;
10. Always vent the gas properly / as per the safe venting procedure;
11. Always use non-sparking tools & tackles for any operation &
maintenance;
12. Always follow guidelines of OEM / CGD Co. / OMC/ Statutory Norms
at all the times.
13. Do ensure that, during CNG filling , adequate illumination is available
at operating and non-operating areas;
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14. Always use FRLS Cables, Flame-proof installations / electrical fixtures

/ equipments etc at the Station , at least for hazardous areas ;
15. Always ensure periodic testing of fire fighting equipments with
necessary marking / tagging on it;
16. Ensure proper Earthing for all the equipments, dispensers, gadgets,
lighting, computers, etc.
17. Use DCP Fire extinguishers for extinguishing the gas fire;
18. Do contact CGD Co’s Control Room & OMC Representative in case
of any Emergency / Accident immediately
19. Always ensure proper house-keeping at Station / fore court at all
the times ;
20. Do report near-miss / hazards reporting to the concerned CGD Co
officials & OMC Representative ;

8.2 Dont’s:
1. Do not leave from vehicle during the filling operation , except in the case of
trickle fill;
2. Do not keep filling hose in such a position that, it causes damages, scratched
on it or to avoid excess wear & tear;
3. Do not use the leaking O-ring on filling nozzle;
4. Do not disturb / reset any installation on your own;

5. Do not use “Ammonia based Soap” for leakage checking , as it will cause
corrosion to the stainless steel / similar Material parts;

6. Do not carry any animals, flammable material, while filling. Keep away all
such materials;
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7. Do not dispense CNG into any other cylinder , other than that in CNG
vehicle cylinder , i.e. not in cylinder for auto-LPG/ Propane or other fuels or in
the spurious / fabricated cylinders. CNG cylinders are made of Seamless Type.

8. Do not dispense CNG into unauthorized vehicle with expired cylinder/ leaky
cylinders / installations / system or incompatible / unsafe filling system;

9. Do not overfill the CNG as per the design / working pressure, i.e. above 200
bar;
10. Do not carry out any welding work on CNG components. It is unsafe;
11. Do not use the CNG Dispenser , if found unsafe, malfunctioning, leaking,
faulty pressure gauge, etc.
12. Do not over tighten any fittings / gadgets;

13. Always, trained, qualified, skilled & physically fit manpower should handle this
job;
14. Do not use damaged, twisted, worn-out, excess length filling hoses;

15. Do not Dispense CNG into any loose cylinders (not mounted on the vehicle);

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Don’t fill CNG in an unauthorised Cylinder as shown below :

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9.0 CRITICAL INFORMATION OF CNG REFUELLING EQUIPMENTS :

9.1 Specifications of Cylinder fitted in CNG Vehicle:

 Min Wall thickness = 7.5 mm

 Water capacity = 25/40/50 Litres +5%

 Test pressure = 425 Bar

 Filling Pressure = 255 Bar at 15 Deg C

9.2 Mounting of Cylinder in a CNG Vehicle :

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9.3 CNG Dispensing Unit - Types

9.3.1 Types of CNG Dispenser :

 Car Dispenser >15 KG/MIN

 Bus Dispenser >75KG/MIN

9.3.2 Safety Features in CNG DU :

 Safety Relief Valve (SRV)
 Excess Pressure cut off.
 Break away coupling
 Emergency Shutdown device (ESD).
 Pressure Gauge at DU .

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9.4 Emergency Isolation Valve at CNG Dispenser :

The function of this valve is to allow and stop flow of gas to the dispensing
line. Isolation valve is mounted on dispenser; by rotating the knob in
clockwise direction (off position) gas supply gets disrupted , while
rotating the knob in anti-clockwise direction (on position) permits gas flow
from dispenser to the refilling hose.

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9.5 Breakaway Coupling at CNG Dispensing Line :

i) This is an additional safety device provided in the dispensing line.
ii) The main function of this is to disrupt the gas supply during any
accidental pulling of hose assembly.
iii). It disconnect long refilling hose from dispenser in case of hose
pulling & isolates gas supply from hose.

Breakaway coupling

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9.6 Emergency Shut-Off Valve at CNG Dispenser :

This is brought in to operation only in case of repair or prolonged
shutdown. This isolation valve is also utilized in quick shut off in the
event of any Gas Leak / Emergency. It is always in open condition during
filling operation. However it has to be always kept in close position while
replacing any part in the downstream of this valve i.e. refueling valve,
main hose, vent hose, break-away coupling, pressure gauges etc.

Emergency Isolation valve as shown in red color.

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9.7 Pressure Gauge at CNG Dispenser for safe operation:

 This is installed on the downstream of the dispenser and mounted
on the front side of the dispenser unit.

 It indicates the pressure of the Gas being filled into the vehicle
Cylinder.

 Below photograph is the pressure gauge mounted on the front

side of CNG Dispenser :

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Annexure-I
Daily Check-List to be filled in by CNG RO Dealers
Name of the Outlet: Date :

Sr.No Description / Particulars Yes Remarks

/ No
1 All dispensing units (DUs) are clean. There is no inflammables
outside the DU.

2 All piping connections in DUs and compressor areas are leak free
and there is no leakage of Gas observed.

3 Emergency Stop switch /button is operational.

4 All Fire Extinguishers are in place and valid for use as on date.

5 All CA are in uniform and wearing PPE eg safety shoes, helmets,

etc.

6 Safety signs are in place (No smoking /Do not operate mobile
phone messages, Display boards for customer, Attendants etc.)

7 Sand in buckets is dry and without any lumps.

8 All light fixtures in the CNG area and periphery, canopy, sales room
are in working condition and no loose wires .

9 Daily briefing of Dos & Don’ts on safety has been carried out by the
dealer to all attendants before start of shift.

10 General House- keeping of CNG area is in good condition. It is

ensured that vehicle engine is switched off at CNG area. CA is
putting Rubber pad on battery terminal

11 PESO Licence is valid & displayed. Important telephone numbers

are displayed.

12 Ensure that Log book is filled by CGD Operator and Work permit if
any issued by CGD Co before any CNG maintenance job . Any
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PROCEDURE (SOP)

AT CNG RETAILOUTLET

Irregularities, to be reported to CGD Co. & OMC field officer.

13 Confirmed that All CNG Attendants are trained with STC Card
issued by CGD Co.

14 Earthing connections are in perfect conditions at all places i.e. DU

(pump/motor/panel), DG, Compressor area by CGD Co operator.

15 The manager/Shift in charge / Senior CNG Attendant in a shift are

well conversant with SOP & safety practices in case of any
Emergencies.

Name of the Dealer / Dealer’s Representative & Signature :

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 GUIDELINES & DOC No: OMC/SP/CNG/31

STANDARD OPERATING Eff. Date : 01-12-2015.

PROCEDURE (SOP)

AT CNG RETAILOUTLET

Thank You for Safe Operations

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