Marina fueling systems require a unique blend of knowledge and skills
By Paul J Doyle – Featured in Marina Dockage magazine
The growing popularity of recreational boating in the U.S., with nearly 30 percent of Americans participating today, is raising the attention level for properly designing, installing and operating marina fueling systems. However, the design and construction of marina fueling facilities is a specialized undertaking that requires knowledge and skills that are unique in combining distinctly different industries.
Marina owners, operators and users tend to believe that the design, engineering, construction and operation of their fueling systems are done properly. A five-year NFPA study showed that this confidence might be misplaced. The study revealed that 90 percent of personal injuries and 75 percent of property damage at marinas resulted from fires fed by flammable and combustible liquids (Service Station Fires: 1991-1995, November 1998).
When it comes to marina fueling system projects, there are two major reasons why only experienced and competent engineers and contractors should undertake the projects.
First, because marinas are situated in harsh environments, the use of standard equipment is impossible. As a result, marinas should only install site-specific, state-of-the-art equipment, such as composite manholes, UV stable double-wall piping, stainless steel weatherproof marina dispensers, fittings, and valves.
Second, the design and construction of marina fueling facilities is a specialized undertaking that requires a unique combination of knowledge and skills from distinctly different industries. The typical petroleum industry fuel system installation engineer or contractor does not construct marina fueling facilities on a frequent basis. As a result, he often has little experience to draw on when undertaking a marina industry project.
Overall goals
The basic goal for the marina fueling system designer is to provide a safe, reliable, and economical system for storing and distributing fuel at an acceptable flow rate into watercraft. At a minimum, the system must be designed to meet the following criteria; fire safety, environmental protection, and worker health and safety.
Design is the first process for a successful marina fueling system. The following codes and publications should be referenced to obtain criteria how a marina fuel system is to be designed and installed.
- NFPA 10–Standards for Portable Fire Extinguishers
- NFPA 30–Flammable and Combustible Liquids Code
- NFPA 30A–Automotive and Marine Service Station Code
- NFPA 70–National Electrical Code, Article 555, Marinas and Boatyards
- NFPA 302–Pleasure and Commercial Motor Craft
- NFPA 303–Marinas and Boatyards
- 33 USC 1321 (1986– Federal Water Pollution Control Act (FWPCA)
- 40 CFR 300–National Oil and Hazardous Substances Pollution Contingency Plan (NCP) PEI
- RP100-05–Recommended Practices for the installation of Underground Storage Systems
- PEI RP200-08–Recommended Practices for the installation of Aboveground Storage Systems for Vehicle Fueling
- PEI RP1000-09 –Recommended Practices for the Installation of Marina Fueling Systems ( being drafted at this time)
If the designer is to create a fuel system that exceeds the customer’s expectations, he must first talk to the client to obtain an understanding of his budget, goals, and target watercraft or vessels. Once this is established, the engineering of the design can begin.
At this juncture, the designer produces detailed engineered drawings that are approved by the client, contractor, and Authorities Having Jurisdiction (AHJ). This is a crucial step in the project because these approved drawings will be used throughout the construction process.
During the permitting phase, the designer and installer will hold numerous meetings with the client to establish a construction schedule. During the scheduling phase state laws require anyone who excavates below the surface to notify utility companies before starting excavation. The contractor must contact Dig Safe System, Inc. to obtain a permit number confirming that the contractor has contacted all the appropriate underground utilities, and they have located and marked their utilities before digging.
The installation process
The design, construction, and installation of underground storage tanks in conjunction with marina fueling systems is generally the same as for other types of motor vehicle fueling systems. Installation of the underground tanks should be in accordance with PEI RP100, Recommended Practices for Installation of Underground Liquid Storage Systems, manufacturer’s instructions, and applicable codes.
Because marina fuel tanks are near navigable water bodies, the underground tanks must be made of double-walled construction. All components must be corrosion resistant. If the tanks are to be located in a high groundwater area or a mapped flood zone, the design of the tank anchoring system should be able to withstand a full submergence of the tanks. Moreover, lockable, water-tight caps are required on all tank risers for high water tables.
When possible, marinas should locate tanks so they are out of the normal travel path of heavy facility equipment, such as forklifts and travel lifts. If the tank cover pad is not designed to carry traffic loads, the marina should install bollards or other barriers to prevent vehicles from driving over the pad. If marina equipment driving over the tank pad cannot be avoided, design the tank cover pad to safely carry the weight of vessel moving equipment loaded to maximum capacity.
The most challenging aspect of marina fueling system installation is routing the piping between the shore and dock. This is especially challenging when fuel dispenser is located on a floating dock that changes significantly due to tidal fluctuations. The design established at the commencement of the project recommends that the piping must be able to withstand a corrosive environment, resist fire and ultraviolet radiation, protected against physical damage, and be flexible enough to accommodate both small scale movement due to wave action and larger scale movement due to water level variations, or periodic tidal changes.
The piping system also includes an onshore transition sump containing shutoff valves, normally closed solenoid valves, and breakaway valves. The installation must also be able to facilitate maintenance and permit draining and disconnection of the piping in the event of a severe storm event.
Contractors need to design and install the pipe within the dock structure so as to provide as much protection from physical damage as practical. They should also install an additional sump with a breakaway valve, as well as a shutoff valve for the piping transition from the gangway to the dock. During the dock installation process at The City Marina Charleston S.C., the piping from the sump was within a sleeve, which assured the piping manufacturer that the piping needed no additional protection, even in the few relatively exposed locations, because protection from physical damage was inherent in the piping design. Piping connections and terminations were made within the secondary containment sumps. Leak sensors were mounted per manufacturer’s specification within all transition and dispenser containment sumps.
In Florida, contractors anchor fuel dispensers in accordance to Florida Building Code 1609.2B. If the dispensers will be subject to high wind loads and flood zones, they should be fastened securely to a solid base using corrosion resistant anchors. (Fastenal Architect &Engineering Guide 6 2002)
The fuel dispensers are required to be installed with a secondary containment piping sump, where a double poppet shear valve is mounted rigidly within the sump. All connections are completed with stainless steel flex hoses.
Stainless steel cabinet dispensers with weather-proof displays are the dispensers of choice. Internally the dispensers have stainless steel piping with stainless steel electric internal hose reels. All fuel hoses are color coded, UV stable, and come with USCG approval.
The nozzles should be compatible with the type of fuel to be dispensed and assist in providing the designed fuel flow rate. Marina nozzles should incorporate features that will help minimize potential fuel spills and drips. Nozzles should not be left unattended during fueling operations. NFPA 30A requires the removal of hold-open latch devices from nozzles intended for marina service.
The proper conduit, fittings, grounding, and wire sizing are installed per the engineered design. Installation follows established electrical codes such as NEC 70 and applicable portions of fueling codes, such as NFPA 30A and the International Fire Code.
Emergency shutoff switches should be placed no closer than 20 feet and no further than 100 feet from each dispensing device. Contractors should install an additional emergency shutoff switch on shore near the access point to the fuel dock to cut-off power to all pumps, fuel dispensing devices, solenoid valves, and electrical circuits in classified areas
An electronic compliance monitoring system is installed per AHJ. The system should be able to capability to perform and print activity reports, reconcile inventory, and monitor the entire fuel system including tanks, piping, all sumps, and fueling locations.
The installation of required signage at all fuel distribution locations and the installation of code compliant fire extinguishers is one the last procedures performed before obtaining a Certification of Occupancy. In addition, certified technicians with a state-approved Prover calibrate and seal all dispensing device meters.
The contractor will present a close-out package to the client. This includes operation and maintenance manuals, as well as warranty paperwork. In many cases, the contract calls for the installer to provide as built drawings and photographs showing the general layout.
Safe operation
Designing and installing marine fuel systems is one thing. The key to the reliable and safe operation of the fuel facility rests with knowledgeable and conscientious facility operators. The safe operation of marina fuel facilities depends on the presence of a trained attendant at all times that the facility is open for fuel dispensing.
Extensive training of employees on the operating systems and proper response to emergency situations is the key to any successful marina fuel system. This training is typically given to personnel designated by the owner when the marina fuel facility is essentially complete, but not yet open for operation.
