Starting a Gas Station Business

							Gasoline Station Reference Manual
 Complying with Washington State and Local
          Air Quality Regulations




            Northwest Clean Air Agency
                 www.nwcleanair.org
             1600 South Second Street
           Mount Vernon, WA 98273-5202
         (360) 428-1617 or (800) 622-4627

                                         Last Updated 6/28/05
  Why did NWCAA produce this booklet?
This manual was developed to inform owners, operators, and
employees of companies dispensing gasoline about air pollution
requirements. The Northwest Clean Air Agency (NWCAA) administers
two programs specifically related to gasoline dispensing facilities:
Stage I Vapor Recovery and Stage II Vapor Recovery. The Air Quality
Compliance Self-Inspection Checklist at the back of this book will help
you stay in compliance with state and local requirements.


Effects of air pollution from gasoline dispensing

The main air pollutants of concern associated with gasoline dispensing
are the vapors that consist of toxic and volatile organic compounds
(VOC). These vapors are released while refilling underground storage
tanks and during vehicle refueling. Breathing these vapors can cause
lung irritation, breathing difficulties, and may even cause cancer.
Capturing gasoline vapors decreases health risks, fire hazards,
unpleasant odors, and improves our air quality.


 This manual contains the following:

• Station construction and modification requirements
• Explanation of Stage I and Stage II vapor recovery systems
• Daily operation and maintenance requirements for your facility’s
   daily operations
• Inspection requirements for your vapor recovery equipment
• Self-inspection sheets for daily or weekly Stage I and II inspections
   (depending on your specific equipment)




                                   2
Gas station construction & modification requirements

 If you are planning to construct a new gas station or modify the vapor
 recovery equipment of an existing one, you must first submit a Notice
 of Construction (NOC) application to the Northwest Clean Air Agency
 (NWCAA). After a review of this application, the NWCAA will issue an
 Order of Approval to Construct (NWCAA Regulation 300) thereby
 granting project approval. Actions that may trigger the permit process
 include, but are not limited to:

       • Changing the type of Stage I vapor recovery system, for
          example, changing from a coaxial to a dual point system
       • Installing new gasoline storage tanks
       • Removing the existing Stage II vapor recovery system

 Please contact the Northwest Clean Air Agency to request a Notice of
 Construction application or to discuss whether a specific modification
 requires a permit. Forms can also be found on our website.

                        (360) 428-1617 (Skagit)
                  (800) 622-4627 (Island & Whatcom)
                  www.nwcleanair.org/regulated/gasoline.html




                                      3
What is Stage I Vapor Recovery?

VOC emissions result from refilling underground storage tanks at
gasoline stations. Stage I vapor recovery systems take the gasoline
vapors that are displaced when filling the underground tanks and
returns them to the truck’s cargo tanks.

There are two types of Stage I systems - dual point and coaxial
(Figures 1 and 2).


Dual point systems have two              Coaxial systems utilize one port
ports. One port is used to deliver       for transporting both liquid
gasoline from the truck to the           gasoline and vapor.
tank, and the other is used to
return vapors to the truck.




                                                      Figure 2
             Figure 1


Does Stage I Vapor Recovery Apply to Me?

Stage I requirements apply to:

     1) gasoline stations dispensing an annual gasoline throughput
        greater than 200,000 gallons, and
     2) all new or modified gasoline stations with a gasoline storage
        capacity greater than 10,000 gallons.




                                     4
 What Are Stage I Vapor Recovery Requirements?

1. Gasoline storage tanks must be equipped with submerged or
   bottom fill lines (end of fill tube must reach within 6" of bottom of
   the gasoline storage tank. See Figure 3) and proper equipment to
   balance gasoline vapors with the delivery transport tank.

2. The owner/operator of a gasoline dispensing facility shall not
   permit the loading of gasoline into a storage tank unless vapor
   balance system is attached to the transport tank and is operated
   satisfactorily (Figure 4)

3. Only California Air Resources Board (CARB) approved vapor
   recovery systems may be installed on the tank(s). These
   approvals can be found at www.arb.ca.gov/vapor/vapor.htm.
   (Note: referred to as Phase I & II instead of Stage I & II.)

4. All Stage I equipment must be installed and tested in accordance
   with the latest revision of the Petroleum Equipment Institute's
   "Recommended Practices for Installation & Testing of Vapor
   Recovery Systems at Vehicle Fueling Sites" Document No.
   PEI/RP300. (This document can be found at www.pei.org.)
 Note: Refilling of underground storage tanks requires proper
 attachment of vapor balance system equipment. Allowing
 gasoline to be delivered without adequate vapor recovery is a
 violation of state law and the owner/operator is subject to
 formal enforcement action.




            Figure 3



                                                Figure 4




                                   5
  What is Stage II Vapor Recovery?

Vapors are displaced from vehicle
gas tanks when fuel is added. The
Stage II system sends the vapors
displaced from the vehicle fuel
tank back into the underground
storage tank using special hoses
and nozzles. Stage I and II vapor
recovery systems capture
approximately 90% of these VOC
emissions. (Figure 5)
The two common Stage II vapor
recovery systems are the vapor
balance and vacuum assist
systems.

The vapor balance system
operates by creating a vacuum in               Figure 5
the underground storage tank as
fuel is removed from the storage
tank and pumped into the vehicle’s
gas tank. The pressure in the fuel
tank forces out the vapors and the        Vapor Balance System
vacuum draws it into the
underground storage tank. A
coaxial hose (hose within a hose)
allows the flow of gasoline to the
vehicle and recovery of vapors at
the same time. A rubber “boot”
around the nozzle creates the tight            Figure 6
seal on the vehicles gas tank
allowing the system to function
properly. (Figure 6)

Vacuum assist Stage II vapor
                                          Vacuum Assist System
recovery systems do not require a
"boot" on the nozzles. Instead, it
draws the vapors from the vehicle
tank into the storage tank using a
vacuum pump located in the
gasoline dispenser. The vacuum
pump speed varies with the speed
of vehicle refueling so that for
each gallon of gasoline dispensed,             Figure 7
one gallon of vapors are pulled
into the station’s underground
storage tanks. (Figure 7)




                                      6
Does Stage II Vapor Recovery Apply to Me?

The NWCAA issues an Order of Approval to Construct (OAC) permit
for all gasoline stations where State II equipment is required. In
some cases OAC permits have been revised allowing the station to
remove Stage II equipment if their residential setback distances meet
the criteria established in Table 1 (WAC 173-491-040 (5)(A)). This
setback distance assures that nearby residences are not adversely
impacted by the toxic compounds found in gasoline vapors.

Table 1
     Gasoline Throughput            Allowable Distance to Nearest
      (millions of gallons)           Residence Property Line*

               1.5                              20   m   (65 ft)
               2.0                              25   m   (82 ft)
               4.0                              38   m   (124 ft)
               6.0                              49   m   (160 ft)
               8.0                              58   m   (190 ft)
              10.0                              66   m   (216 ft)

 *Stage II vapor recovery is required if under these distance
                            limits

*Note: Stage II equipment cannot be removed from a station
without a Notice of Construction approval from the Northwest Clean
Air Agency.

  What Are Stage II Vapor Recovery Requirements?


1. If Stage II vapor recovery equipment is installed, it must be a
   California Air Resources Board (CARB) certified system. CARB
   approved Stage II vapor recovery systems are certified under
   Executive Orders. CARB Executive Orders for Stage II systems can
   be viewed at http://www.arb.ca.gov/vapor/ophaseII.html.

2. Stations operating with a Stage II vapor recovery system must
   operate that system in accordance with the associated CARB
   Executive Order and the Order of Approval to Construct (OAC)
   issued by the Northwest Clean Air Agency.

3. Stage II plumbing must be installed in accordance with the latest
   revision of the Petroleum Equipment Institute's "Recommended
   Practices for Installation & Testing of Vapor Recovery Systems at
   Vehicle Fueling Sites," Document No. PEI/RP300.

4. Stage II vapor recovery lines must have a uniform slope of at least
   1/8 inch per foot back to the tank to prevent liquid traps.
                                   7
 5. Stage II vapor recovery equipment must be installed in accordance
    with the system's certification requirements and be maintained
    leak free, vapor tight, and in good working order.

 6. If Stage II equipment is determined to be defective, the
    owner/operator must take the system out of service until it is
    repaired, replaced, or adjusted to function properly.

 7. Owners/operators must post operating instructions for Stage II
    systems in the gasoline dispensing areas to instruct customers not
    to “top off”.

What are the Testing Requirements for Stage I and II
Systems?

 NWCAA requires periodic testing of the Stage II vapor recovery
 equipment. CARB vapor recovery test methods are available at
 http://www.arb.ca.gov/testmeth/vol2/vol2.htm/new2003vol2.htm .

 The following four tests are typically required upon start-up.
 Additionally, tests #3 and #4 are required to be conducted annually.

 1. The dynamic pressure test (a.k.a. "back pressure test" or
    "blockage test") ensures there is no excessive back pressure,
    generally due to low spots in the Stage II underground piping. This
    test is conducted wet and dry (the wet portion is what is typically
    called the "blockage test"). The measured back pressures are
    compared to allowable values for each Stage II system. Higher
    back pressures are allowed for vacuum assist systems than for
    vapor balance systems because the vacuum is capable of
    overcoming slight low spots in the piping where gasoline vapor can
    condense.

 2. The static torque test is only required for facilities with fill tube
    adapters that are designed to rotate. This test quantifies the
    amount of static torque required to start the rotation of a rotatable
    Stage I adapter. This procedure is also used to verify that a Stage
    I adapter rotates at least 360 degrees. Each CARB Executive
    Order specifies the acceptable static torque values.

 3. The static pressure integrity test (a.k.a. "pressure decay test" or
    "static pressure decay test") quantifies the vapor tightness of the
    vapor recovery system to ensure there are no leaks. The entire
    vapor recovery system is pressurized with nitrogen, and the
    system pressure is allowed to decay. After five minutes, the
    pressure is compared with the allowable value that is based on
    the size of the tank and how much gasoline is in it.

 4. The air-to-liquid ratio test is only required for facilities with
    vacuum assist Stage II systems. This test quantifies the
                                       8
   air-to-liquid volume ratio to make sure the correct amount of
   vacuum is being pulled at each nozzle. Each CARB Executive
   Order specifies the acceptable air-to-liquid ratio values.

 Are There Changes to the CARB Certification?

On April 1, 2001, the California Air Resources Board (CARB) adopted
Enhanced Vapor Recovery (EVR) amendments to its vapor recovery
certification and test procedures for gasoline loading (Stage I) and
motor vehicle gasoline refueling (Stage II). These new stringent
standards and new equipment specifications for both Stage I and II
increase vapor recovery to at least 98% efficiency. In accordance
with the EVR regulations all existing CARB certifications will expire
four years from the effective date of new EVR standards. This means
that new installations must comply with the new CARB requirements,
as certified systems become available.

The Northwest Clean Air Agency is not currently requiring the phase
out of non-EVR systems. However, when new Stage II equipment is
installed, it must be EVR certified. More information about EVR
requirements and implementation guidelines is available at
http://www.arb.ca.gov/vapor.htm .

 How Effective are Vapor Recovery Systems in
 Reducing Emissions?

Below are emission reduction calculations for comparison using three
scenarios: 1) No controls, 2) Stage I vapor recovery, and 3) Stage I
and II vapor recovery. The calculations are based on an annual
throughput of one million gallons and include emissions from
underground storage tank filling (controlled with Stage I) and vehicle
refueling operations (controlled with Stage II).

Table 2

Type of             Emissions          Emissions           Total
Control                from          from vehicle        Emissions
                    Tank filling       refueling          (lb/yr)
                      (lb/yr)           (lb/yr)

No Controls           12,500             11,700            24,200

Stage I vapor          1,300             11,700            13,000
recovery

Stage I and            1,300             1,800              3,100
Stage II vapor
recovery

* Note: Controlling vaporous emissions saves you money (7 lbs
vapors ~ 1 gallon gasoline).
                                9
 Facilities with Stage I vapor                   Facilities with both Stage I and
  recovery reduce total VOC                      Stage II vapor recovery reduce
                                                  total VOC emissions by 87%
emissions by 46%. (Figure 8)
                                                             (Figure 9)




                                  Uncontrolled
                                  Controlled




          Figure 8                                            Figure 9




                                 10
Requirements relating to daily operations include:

                                                Cap & Gasket, Top View
 1. Stage I vapor recovery equipment
    must be in good working condition at
    all times.

 2. The protective caps must be on tight
    and locked down unless actively
    loading fuel into underground
    storage tanks. Sealing gaskets and               Figure 10
    poppet valves must be in good
    working condition. (Figure 10, 11,
    12, 13)                              Adapter with Poppet Valve, Cut
                                                  Away Side View
 3. Maintenance records must be
    kept for the previous 24 months
    of operation, and must include
    date and nature of maintenance
    and all certification tests
    performed.
                                                    Figure 11
 4. The owner/operator must display
    a copy of the
    Northwest Clean Air Agency’s
    Annual Registration Certificate at         Dual Point Drop Tube
    the facility and keep a copy of            Cut Away Side View
    their OAC readily available.

 5. Records of the total annual
    gasoline throughput (sales) for
    the current year and two previous
    years must be kept and available
    on-site for inspection by
    Northwest Clean Air Agency staff
    during normal business hours.                   Figure 12

 6. Stations with
    vapor balance Stage II systems
    must check for damaged nozzle           Coaxial Drop Tube & Gasket
    faceplates and torn boots and              Cut Away Side View
    hoses.




                                                    Figure 13
                                  11
 What Does NWCAA Look for During a Facility
 Inspection?

The Northwest Clean Air Agency inspectors visit stations annually to
conduct compliance inspections. Inspectors check the vapor recovery
systems to ensure everything is in good working order. This includes
checking all components to see that they are properly CARB certified
and defect-free. Because equipment should be in good working order
throughout the year, inspectors may come at any time during the
year without notice.

 What Happens If I Violate NWCAA’s Regulations?

Penalties for violating air pollution regulations can exceed $10,000
per violation, per day. Remember, reducing VOCs provides for a
safer workplace and healthier environment. The most effective way
to comply with air quality regulations is to know what your
requirements are and conduct regular self inspections to assure that
the facility maintains continuous compliance. Nobody wants surprises
during an inspection, including the inspector and station personnel.
Make sure everyone at your facility understands and follows all
applicable vapor recovery requirements.

 How Will a Self-Inspection Checklist Help Me?

A self-inspection checklist is a good tool to help ensure that your
facility is in compliance. The information in this guide covers the
basic requirements you need to know, and will help you prepare for
periodic air pollution control inspections. An example of a self-
inspection checklist is included at the end of this booklet, but you
may want to come up with a specific checklist for your facility.

You should regularly check your vapor recovery system using your
self-inspection checklist to ensure everything is in good working
condition. Identify any potential problems and take action.
Replace or repair defective components immediately. Do your
part to help yourself, your customers, and the environment.




                                  12
 What Other Agencies Regulate Gas Stations?

WA State Department of Ecology - Underground Storage Tank
Program
NW Regional Office
Bellevue, WA
(800) 826-7716
(425) 649-7000
http://www.ecy.wa.gov/programs/TCP/ust-lust/tanks.html


 Where Can I Find More Information About Vapor
 Recovery?

Northwest Clean Air Agency
www.nwcleanair.org/regulated/gasoline.html


Environmental Protection Agency, Region 10
1200 Sixth Avenue
Seattle, WA 98101
Tel: (206) 553-1200
www.epa.gov


California Air Resources Board
www.arb.ca.gov/vapor/vapor.htm


American Petroleum Institute
1220 L Street N.W.
Washington, D.C. 20005
Tel: (202) 682-8000
www.api.org


The Petroleum Equipment Institute
P.O. Box 2380
Tulsa, OK 74101
www.pei.org




                                      13
Gas Station Contractors and Equipment


Cannon Electric                      W L Repair
P.O. Box 983                         959 W. Laurel
Bellingham, WA 98227                 Ferndale, WA 98248
Tel: (360) 733-4070                  Tel: (360) 384-4678
Fax: (360) 676-4529                  Fax: (360) 383-0044

NW Pump                              APS Services
22914 64th Ave. S                    117 Frontage Rd. N.
Kent, WA 98032                       Pacific, WA 98047
Tel: (253) 850-7867 or (800) 482-    Tel: (800) 660-6557
PUMP                                 Fax: (253) 735-2678
Fax: (253) 850-5402

Ace Tank & Equipment Co.             ESE Corporation
1143 Elliot Ave. W.                  11011 Waller Rd. E.
Seattle, WA 98119                    Tacoma, WA 98446
Tel: (800) 426-2880                  Tel: (253) 535-3112
Fax: (206) 281-5030                  Fax: (253) 535-3298

Evergreen Environmental              Pacific Environmental Services
17108 9th Ave. SE                    Co.
Mill Creek, WA 98012                 P.O. Box 2049
Tel: (800) 457-8986                  Port Townsend, WA 98368
Fax: (425) 787-7812                  Tel: (800) 222-9212
                                     Fax: (360) 379-9395

Pacific Northern Environmental       SME
Corp.                                2302 A St.
1081 Columbia Blvd.                  Tacoma, WA 98402
Longview, WA 98633                   Tel: (253) 572-3822
Tel: (503) 247-3437                  Fax: (253) 572-0978
Fax: (360) 423-2272
Tanknology                           Northwest Environmental
West Kettleman Ln. Suite “T”         Solutions
Lodi, California 95242               P.O. Box 518
Tel: (800) 964-0180                  Sumner, WA 98390
Fax: (209) 365-1543                  Tel: (253) 241-6213
                                     Fax: (253) 770-3114
Northwest Tank                       Nebar Supply Co.
1720 100th Place SE Suite 101        430 Minor Ave. N.
Everett, WA 9808                     Seattle, WA 98109
Tel: (800) 742-9620                  Tel: 800-552-7277
Fax: (425) 338-9749                  Fax: 206-623-5947

Fuel Tank Services L.L.C.            Ultra Tank Services Inc.
P.O. Box 30096                       P.O. Box 30096
Bellingham, WA 98228                 Bellingham, WA 98228
Tel: (360) 815-7540                  Tel: (360) 815-5361
Fax: (360) 398-2311                  Fax: (360) 398-2311
                                    14
NOTES




 15