PEI/RP600-18

Recommended Practices
for Overfill Prevention
for Shop-Fabricated
Aboveground Tanks
 PEI/RP600 -2018

Other Reference Publications Available From PEI

Order online at www.pei.org/shopping

• PEI/RP100, Recommended Practices for Installation of Underground Liquid Storage

Systems

• PEI/RP200, Recommended Practices for Installation of Aboveground Storage Systems for

Motor-Vehicle Fueling

• PEI/RP300, Recommended Practices for Installation and Testing of Vapor-Recovery

Systems at Vehicle-Fueling Sites

• PEI/RP400, Recommended Procedure for Testing Electrical Continuity of Fuel

Dispensing Hanging Hardware

• PEI/RP500, Recommended Practices for Inspection and Maintenance of Motor Fuel

Dispensing Equipment

• PEI/RP700, Recommended Practices for the Design and Maintenance of Fluid-

Distribution Systems at Vehicle Maintenance Facilities

• PEI/RP800, Recommended Practices for Installation of Bulk Storage Plants

• PEI/RP900, Recommended Practices for the Inspection and Maintenance of UST Systems

• PEI/RP1000, Recommended Practices for the Installation of Marina Fueling Systems

• PEI/RP1100, Recommended Practices for the Storage and Dispensing of Diesel Exhaust
Fluid (DEF)

• PEI/RP1200, Recommended Practices for the Testing and Verification of Spill, Overfill,
Release Detection and Secondary Containment Equipment

• PEI/RP1300, Recommended Practices for the Design, Installation, Service, Repair and
Maintenance of Aviation Fueling Systems
• PEI/RP1400, Recommended Practices for the Design and Installation of Fueling Systems
for Emergency Generators, Stationary Diesel Engines and Oil Burner Systems

• PEI/RP1500, Recommended Practices for the Design, Installation, Operation and

Maintenance of Compressed Natural Gas Vehicle Fueling Facilities

• PEI/RP1600, Recommended Practices for the Design, Installation, Operation and

Maintenance of Liquefied Natural Gas Vehicle Fueling Facilities (Scheduled release in
2019.)

• PEI/RP1700, Recommended Practices for the Closure of Underground Storage Tanks

and Shop-Fabricated Aboveground Storage Tanks (Scheduled release in 2018.)

ii pei.org
 Recommended Practices for Overfill Prevention for Shop-Fabricated Aboveground Tanks

FOREWORD
These Recommended Practices for Overfill Prevention for Shop-Fabricated Aboveground Tanks have been
prepared as an industry service by the Petroleum Equipment Institute. The text represents the consensus
views of the PEI Aboveground Tank Overfill Prevention Committee, comprised of the following members:

Sonny Underwood, Chairman Brad Holmes

Mid-South Steel Products, Inc. Clay & Bailey Mfg. Co.
Cape Girardeau, Missouri Kansas City, Missouri

Shawn Kiefer
John Albert Total Control Systems
MO Department of Agriculture Fort Wayne, Indiana
Jefferson City, Missouri

Alfred Reid
Tracy Barth Broward County Environmental Protection
MFA Oil Company Department
Columbia, Missouri Plantation, Florida

Chris Collura Dana Schmidt

Guardian Fueling Technologies Steel Tank Institute
Tampa, Florida Lake Zurich, Illinois

Terry D. Cooper Jeff Smith

Acterra Group, Inc. Liquid Automation, LLC
Marion, Iowa Alpharetta, Georgia

Previously serving as consultant to the committee was Marcel Moreau, Marcel Moreau Associates,
77 Ocean Avenue, Portland, Maine 04103.

All questions and other communications relating to this document should be sent only to PEI Headquarters,
addressed to the attention of the PEI Aboveground Tank Overfill Prevention C
­ ommittee.

Petroleum Equipment Institute

P.O. Box 2380
Tulsa, OK 74101-2380
Phone: (918) 494-9696
Fax: (918) 491-9895
E-mail: RP@pei.org
www.pei.org

© 2018 Petroleum Equipment Institute

No part of this document may be reproduced without permission of PEI.

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DISCLAIMER

Every effort has been made by the PEI Aboveground Tank Overfill Prevention Committee to ensure the accu-
racy and reliability of the information contained in this document. However, the Committee, its consultant,
and the Petroleum Equipment Institute make no representation, warranty or guarantee in connection with the
publication of these recommended practices. The Institute hereby expressly disclaims any liability or respon-
sibility for loss or damage resulting from the use of these recommended practices; for the violation of any
federal, state or municipal regulation with which these practices may be in conflict; or for the infringement of
any patent resulting from their use.
 Recommended Practices for Overfill Prevention for Shop-Fabricated Aboveground Tanks

CONTENTS
Foreword................................................................................................................................................... iii

SECTIONS

1. Introduction........................................................................................................................................ 1
1.1 Background................................................................................................................................................................... 1
1.2 Purpose.......................................................................................................................................................................... 1
1.3 Scope............................................................................................................................................................................. 1
1.4 Sources.......................................................................................................................................................................... 2
1.5 Use of Other PEI Recommended Practices.................................................................................................................. 2
1.6 Regulations.................................................................................................................................................................... 2

2. Definitions.......................................................................................................................................... 3
2.1 Aboveground Tank........................................................................................................................................................3
2.2 Alarm Level..................................................................................................................................................................3
2.3 Alternative Fuel............................................................................................................................................................. 3
2.4 API 12F Tank................................................................................................................................................................3
2.5 API 650, Appendix J Tank............................................................................................................................................3
2.6 Atmospheric Tank.........................................................................................................................................................3
2.7 Attended Facility........................................................................................................................................................... 3
2.8 Authority Having Jurisdiction (AHJ)............................................................................................................................ 3
2.9 Bonding......................................................................................................................................................................... 3
2.10 Bottom Loading............................................................................................................................................................3
2.11 Class I Liquid................................................................................................................................................................ 3
2.12 Direct Fill...................................................................................................................................................................... 3
2.13 Electrical Shutoff Switch..............................................................................................................................................3
2.14 Flow Restriction Valve..................................................................................................................................................3
2.15 Fuel................................................................................................................................................................................ 3
2.16 Generator Base Tank.....................................................................................................................................................4
2.17 Grounding...................................................................................................................................................................... 4
2.18 Listed............................................................................................................................................................................. 4
2.19 Loose Fill......................................................................................................................................................................4
2.20 Manifolded Fill.............................................................................................................................................................. 4
2.21 Maximum Operating Level........................................................................................................................................... 4
2.22 Mechanical Shutoff Valve.............................................................................................................................................4
2.23 Obround Tank................................................................................................................................................................4
2.24 Operator(s)....................................................................................................................................................................4
2.25 Overfill Alarm............................................................................................................................................................... 4
2.26 Overfill Incident............................................................................................................................................................ 4
2.27 Overfill Level................................................................................................................................................................ 4
2.28 Overfill Prevention Device........................................................................................................................................... 4
2.29 Petroleum Product......................................................................................................................................................... 4
2.30 Pumped Delivery........................................................................................................................................................... 4
2.31 Qualified Personnel....................................................................................................................................................... 4
2.32 Qualified Technician.....................................................................................................................................................4
2.33 Railcar Tanker...............................................................................................................................................................4
2.34 Remote Fill.................................................................................................................................................................... 4
2.35 Safety Data Sheet (SDS)............................................................................................................................................... 4
2.36 Shutoff Level.................................................................................................................................................................5
2.37 Spill Kit......................................................................................................................................................................... 5
2.38 Stationary Tank.............................................................................................................................................................5
2.39 Storage Tank..................................................................................................................................................................5
2.40 Supply Tank...................................................................................................................................................................5
2.41 Tank Vehicle..................................................................................................................................................................5

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 PEI/RP600 -2018

2.42 Tank Vehicle Operator...................................................................................................................................................5

2.43 Tight Fill........................................................................................................................................................................5
2.44 Top Loading..................................................................................................................................................................5
2.45 Unattended Facility....................................................................................................................................................... 5
2.46 UL 80 Tank....................................................................................................................................................................5
2.47 UL 142 Tank..................................................................................................................................................................5
2.48 UL 2085 Tank................................................................................................................................................................5
2.49 Ullage............................................................................................................................................................................ 5
2.50 Usable Ullage................................................................................................................................................................ 5
2.51 Vent Whistle..................................................................................................................................................................5

3. Safety................................................................................................................................................ 6
3.1 General.......................................................................................................................................................................... 6
3.2 Responsibility................................................................................................................................................................ 6
3.3 Chemical Hazards......................................................................................................................................................... 6
3.4 Fire and Explosion Hazards.......................................................................................................................................... 7
3.5 Electrical Hazards......................................................................................................................................................... 7
3.6 Personnel Hazards......................................................................................................................................................... 7
3.7 Fall Hazards..................................................................................................................................................................8
3.8 Personal Protective Equipment..................................................................................................................................... 8
3.9 Responding to Fuel Spills............................................................................................................................................. 8
3.10 Vehicle Hazards.............................................................................................................................................................8

4. Elements of Effective Overfill Prevention............................................................................................. 9

4.1 General.......................................................................................................................................................................... 9
4.2 Qualified Personnel....................................................................................................................................................... 9
4.2.1 Relevant Knowledge Areas.............................................................................................................................. 9
4.2.2 Attended Facilities........................................................................................................................................... 9
4.2.3 Unattended Facilities.....................................................................................................................................10
4.3 Product Transfer and Emergency Response Procedures.............................................................................................10
4.3.1 Planning the Delivery.................................................................................................................................... 10
4.3.2 Arriving at the Site......................................................................................................................................... 10
4.3.3 Calculating Usable Ullage............................................................................................................................. 11
4.3.4 Checking Equipment...................................................................................................................................... 11
4.3.5 Setting Up the Delivery................................................................................................................................. 11
4.3.6 Initiating the Delivery.................................................................................................................................... 11
4.3.7 Monitoring the Delivery................................................................................................................................ 11
4.3.8 Completing the Delivery................................................................................................................................ 12
4.3.9 Emergency Planning and Response...............................................................................................................12
4.4 Equipment Inspection, Maintenance and Testing.......................................................................................................12
4.4.1 Inspection and Maintenance.......................................................................................................................... 12
4.4.2 Testing............................................................................................................................................................13
4.4.3 Component Documentation........................................................................................................................... 13

5. Overfill Prevention Devices............................................................................................................... 14

5.1 General........................................................................................................................................................................ 14
5.2 Selecting Overfill Equipment...................................................................................................................................... 14
5.3 Testing Overfill Prevention Equipment......................................................................................................................14
5.4 Types of Overfill Prevention.......................................................................................................................................14
5.5 Mechanical Flow Shutoff and Flow Restriction Valves.............................................................................................15
5.5.1 Appropriate Uses...........................................................................................................................................15
5.5.2 Limitations..................................................................................................................................................... 15
5.5.3 Installation...................................................................................................................................................... 15
5.5.4 Inspection and Maintenance.......................................................................................................................... 16
5.5.5 Testing............................................................................................................................................................16
5.6 Electrical Shutoff Switches.........................................................................................................................................16
5.6.1 Appropriate Uses...........................................................................................................................................17
5.6.2 Limitations..................................................................................................................................................... 17

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 Recommended Practices for Overfill Prevention for Shop-Fabricated Aboveground Tanks

5.6.3 Installation...................................................................................................................................................... 17
5.6.4 Inspection and Maintenance.......................................................................................................................... 17
5.6.5 Testing............................................................................................................................................................17
5.7 Electrically Operated and Mechanical Vent Alarms...................................................................................................17
5.7.1 Appropriate Uses...........................................................................................................................................17
5.7.2 Limitations..................................................................................................................................................... 18
5.7.3 Installation...................................................................................................................................................... 18
5.7.4 Inspection and Maintenance.......................................................................................................................... 19
5.7.5 Testing............................................................................................................................................................19
5.8 Mechanical Vent Whistles...........................................................................................................................................19

6. Special Situations............................................................................................................................. 20
6.1 General........................................................................................................................................................................ 20
6.2 Manifolded Filling......................................................................................................................................................20
6.2.1 Installation...................................................................................................................................................... 20
6.2.2 Operation........................................................................................................................................................ 20
6.3 Generator Base Tanks..................................................................................................................................................21
6.3.1 Installation...................................................................................................................................................... 21
6.3.2 Operation........................................................................................................................................................ 21
6.4 UL 80 Tanks................................................................................................................................................................21
6.4.1 Limitations..................................................................................................................................................... 22
6.4.2 Installation...................................................................................................................................................... 22
6.4.3 Inspection and Maintenance.......................................................................................................................... 22
6.4.4 Testing............................................................................................................................................................22
6.4.5 Operation........................................................................................................................................................ 22
6.5 Used Oil Tanks............................................................................................................................................................22
6.5.1 Installation...................................................................................................................................................... 23
6.5.2 Operation........................................................................................................................................................ 23
6.6 Alternative Fuels......................................................................................................................................................... 23
6.6.1 Operation........................................................................................................................................................ 23

7. Gauges............................................................................................................................................. 24
7.1 General........................................................................................................................................................................ 24
7.1.1 Appropriate Uses...........................................................................................................................................24
7.1.2 Limitations..................................................................................................................................................... 24
7.1.3 Installation...................................................................................................................................................... 24
7.1.4 Inspection and Calibration............................................................................................................................. 24

8. Electrical Installation........................................................................................................................ 25
8.1 General Requirements................................................................................................................................................. 25
8.2 Classifications............................................................................................................................................................. 25
8.3 Electrical Equipment................................................................................................................................................... 25
8.4 Wiring..........................................................................................................................................................................25
8.5 Intrinsically Safe......................................................................................................................................................... 25
8.6 Cathodic Protection Systems......................................................................................................................................25
8.7 Grounding and Bonding.............................................................................................................................................. 25
8.8 Provide Uninterrupted Power...................................................................................................................................... 26

APPENDICES

Appendix A: Calculating the Installation Height of Overfill Prevention Devices........................................... 27

A.1 General........................................................................................................................................................................ 27
A.2 Vertical Cylindrical and Rectangular Tanks................................................................................................................27
A.3 Horizontal Cylindrical Tanks......................................................................................................................................28
A.4 Obround Tanks............................................................................................................................................................29

Appendix B: Publication Reference......................................................................................................................................... 31

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