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Regulatory Standards for Fuel Tank Overfill Protection
Fuel tank overfill protection is a critical aspect of safety and environmental responsibility in industries that handle flammable and combustible liquids.
Understanding the Importance of Overfill Protection
Overfilling a fuel tank can lead to a range of issues including spills, environmental contamination, and potential fire hazards. Properly functioning overfill prevention systems are essential to mitigate these risks and ensure safe and efficient operations.
Key Features of Compliant Overfill Protection Systems
There are several features that are critical for effective overfill protection, many of which are mandated by the AS1940 standard.
These features are generally seen across various fuel types and can be found in both mechanical and electronic systems. They include:
- Automated Shutoff – Systems like Banlaw’s FillSafe™ DEFender useS an automated shutoff feature that stops the flow of liquid when the tank reaches its safe fill level. This prevents overfilling and reduces the risk of spills.
- High-Level Alarms – For above-ground tanks holding more than 5,000 litres of flammable liquid or 25,000 litres of combustible liquid, a high-level alarm is now required. These alarms alert operators to the tank’s fill level, giving them time to prevent overfills.
- Safe Fill Levels – According to the AS1940 standard, the safe fill level of a tank is limited to no more than 95% of the tank’s capacity. This standard practice helps prevent overfills due to expansion of the liquid or other factors.
- Pressureless Systems – Banlaw’s FillSafe systems are pressureless, avoiding tank rupture and fatigue.
- Compatibility – Overfill protection systems should be compatible with the liquids being stored, whether that is diesel, DEF, or other liquids. The use of flush-faced couplings, like Banlaw’s DEFMate, ensures no leaks, spills or dirt.
- Spill Response Kits – A spill response kit is now mandatory for sites handling Class 3 flammable liquids. The kit should contain absorbent pads, booms, loose absorbents, and contaminated waste bags, packed in a weather-resistant container.
Key Features of Compliant Overfill Protection Systems
“The storage and handling of flammable and combustible liquids,” is a comprehensive Australian Standard that provides requirements for the safe management of flammable and combustible liquids and guidelines for the storage and handling of flammable and combustible liquids. This standard plays a key role in shaping state and territory fuel storage legislation and is a critical reference for safe fuel handling.
AS 1940:2017 aims to promote the safety of persons and property where flammable or combustible liquids are stored or handled1. It provides minimum acceptable safety requirements and technical guidance to assist in compliance with risk management requirements set by Safe Work Australia and relevant legislation.
The standard applies to commonly used flammable and combustible liquids such as hydrocarbons and industrial solvents, while also acknowledging that some liquids may require additional precautions due to their specific properties. It is particularly relevant for managing the flammability aspects of dangerous goods with a Class 3 subsidiary risk.
This standard covers various aspects of storage and handling, including:
- Planning, design, construction, and safe operation of installations
- Minor storage
- Package storage and handling
- Storage in tanks
- Fuel dispensing
- Piping and tank auxiliaries
- Operations
- Fire protection facilities
The standard also includes appendices that address specific technical aspects:
- Tank venting
- Combustion characteristics
- Fire exposure protection
- Gas-freeing precautions and principles
- Power station and grid transformers
Banlaw's Overfill Protection Systems
Banlaw offers two families of overfill prevention products – FillSafe Zero and FillSafe Power, designed for various industrial uses.
- FillSafe Power is an electronic system suitable for various fluid types and flow rates. It can provide exact tank level feedback and offers multiple pre-set fill levels.
- FillSafe Zero is a hydraulically powered mechanical system optimised for diesel. It does not require an external power source.
Both systems provide reliable tank overfill protection, efficient design with superior flow characteristics, and no pressure build-up in the tank. They also offer a secondary backup shut-off when used with Banlaw Dry Break refuelling nozzles, receivers, and vents.
Overfill Prevention in Underground Storage Tanks
For underground storage tanks (USTs), overfill prevention is also required for tanks that are filled with more than 25 gallons of product at one time. There are three common types of overfill protection for USTs:
- Overfill Alarm – These alarms alert the delivery person when the product reaches a certain level in the tank, giving them time to shut off product flow.
- Automatic Shutoff Devices – These devices stop the flow of product when a certain level is reached.
- Ball Float Valves – These valves slow the product flow by preventing vapours from leaving the tank when a certain level is reached.
Other Considerations
- Electrical Installation – For flammable storage, electrical installation requirements are very strict and must comply with AS3000. Equipment must have explosion-proof connections.
- Signage – Proper signage is essential for flammable storage areas to comply with regulations.
- Dispenser – When storing flammable liquids, the dispenser needs to be mounted remotely due to hazardous area zoning around the tank.
- Training and Competency – Workers involved in fuel handling and transfer need proper training and supervision.
- Risk Management – Employers are obligated to consult with employees about risk management and to use a hierarchy of controls to eliminate or reduce risks.
Adherence to standards like AS1940 is essential for safe and compliant operations. The use of automated shutoff systems, high-level alarms, proper electrical installation, and adherence to safe fill levels all contribute to an effective overfill prevention.
To learn more about our fuel tank overfill protection systems, please contact Banlaw and we’ll connect you with a specialist.
