Spill and Overfill Control

Tank owners and operators are responsible for ensuring that fuel spills or overfills do not occur during fuel
deliveries.

As the person responsible for ensuring that spills and overfills do not happen, it is useful to follow the
same delivery procedure each time an underground storage tank (UST) is filled. The procedure should
include the following measures:

• Ensure there is enough room in the tank BEFORE each delivery. MEASURE the fuel level in the
tank before the delivery;

• Monitor all fuel deliveries from beginning to end;

• Inspect all spill buckets routinely (before and after each delivery); and

• Contain, report and cleanup all spills. Have spill cleanup materials available for small and large
spills, post emergency phone numbers in a conspicuous place so the spill can be reported to the
appropriate authorities.

[Note: Spills or overfills of less than 25 gallons that are contained and immediately cleaned up do not have
to be reported. Spills or overfills greater than 25 gallons must be reported to the North Dakota
Department of Health (701.328.5166) within 24 hours of their discovery and the Environmental Incident
Reporting website at https://www.ndhealth.gov/EHS/wm/EnvironmentalIncidentReporting.aspx.]

North Dakota UST Operator Training Program Spill and Overfill Control 1
Spill Buckets

A spill bucket is a liquid-tight container that surrounds

the fill pipe. They typically range in size from 5 to 25
gallons, and are there to catch and contain any small
leaks, drips and spills from the delivery hose during the
fuel delivery process.

The spill bucket is not designed to contain fuel for long

periods of time. After each delivery, operators should
empty and dispose of the contents properly.

All tanks must be equipped with a spill bucket if the tank

system is filled by transfers of more than 25 gallons at
one time. Spill bucket

North Dakota UST Operator Training Program Spill and Overfill Control 2
Spill Buckets

What a tank operator should look for when inspecting spill

buckets?

• Are the lids in good condition? Chipped spill bucket

lids, and lids that do not fit securely allow water to
enter the bucket.

• Is the spill bucket free of debris, liquid or ice? Water

and/or fuel sitting in spill buckets will damage the
buckets over time.

• Is the spill bucket free of cracks or holes? Cracks or An example of a clean spill bucket

holes in the bucket itself allow fuel to leak out. If a

spill bucket is damaged it needs to be repaired or
replaced.

• Are the drain valves operational? If the drain valve is

left open it can allow water and debris to enter the
tank? [NOTE: Not all spill buckets have drain valves.]

North Dakota UST Operator Training Program Spill and Overfill Control 3
 Spill Buckets

Spill buckets are maintenance items that must be periodically replaced. Given their exposure to
weather extremes, they have relatively short lives - often less than 10 years.

Spill buckets are not supposed to store liquid, and must be kept clean and emptied expeditiously. Common maintenance problems are
illustrated in the pictures above. The spill bucket on the left contains fuel. The middle spill bucket is severely damaged and cannot
contain a spill. The spill bucket on the right contains rainwater and cannot hold any fuel that may be spilled while filling the tank.

North Dakota UST Operator Training Program Spill and Overfill Control 4
Overfill Prevention

The underground storage tank (UST) rules require that an overfill device must be installed on all
tanks that are filled by fuel transfers of more than 25 gallons at one time.

Since tank owners and operators are responsible for ensuring that fuel overfills do not occur, the
overfill prevention device is essentially the BACKUP if the right amount of fuel is not ordered
or delivered.

The function of overfill prevention devices is to stop or restrict the flow of product into the tank or
alert the operator BEFORE the tank is filled to the top. There needs to be enough room in the tank
to drain the fuel left in the delivery hose after the fuel transfer is complete.

There are three types of overfill protection devices:

1. Automatic shutoff devices (also known as drop tube shutoff devices or “flapper” valves)
2. Overfill alarms (electronic alarms)
3. Ball-float valves (also known as float-vent valves)

The operator must determine what type of overfill prevention is installed on the UST system.

North Dakota UST Operator Training Program Spill and Overfill Control 5
Overfill Prevention

Drop-Tube Shutoff Valves

The drop tube shutoff valve is a mechanical device installed in

line with the drop tube. A drop tube is a thin aluminum tube
located inside the tank fill-pipe riser that extends close to the
bottom of the tank. The drop tube minimizes vapors created
during a fuel delivery.
Drop-tube shutoff valve can be
Typically, there is a float-activated mechanism on the outside of seen in the fill pipe
the drop tube that releases a valve, or flapper, inside the drop
tube when the liquid level in the tank reaches 95% of full-tank
capacity. The shutoff valve should be positioned so that the
float arm is not obstructed and can move through its full range
of motion.

Drop-tube shutoff valve

North Dakota UST Operator Training Program Spill and Overfill Control 6
Overfill Prevention

Drop Tube Shutoff Valves

When the shutoff valve is released, the product flowing down the fill pipe slams it shut, severely
restricting the flow of fuel into the tank.

The delivery hose “jumps” when the flapper closes, alerting the transport driver that the tank is
nearly full. The driver should immediately close the delivery valve, and drain any remaining fuel in
the hose into the tank. To notice the hose “jump,” the delivery driver must watch the delivery
hose, not sit inside the truck or building.

North Dakota UST Operator Training Program Spill and Overfill Control 7
Overfill Prevention

Drop Tube Shutoff Valves

Drop tube shutoff valves work well as long as they are used and maintained properly. There are
several potential problems with drop tube shutoff valves to consider:

• Drop tube devices must not be disabled or bypassed. A gauge stick in a fill pipe prevents
the drop tube shutoff valve from closing. If a gauge stick is discovered in a fill pipe, it
should be removed and a service technician called to inspect the overfill valve and ensure it
operates properly.

• The sudden closing of the drop tube valve transmits considerable stress to the delivery
system. The hose connections to the tank and truck must be secure or they may pop off,
creating a significant surface spill.

• There must be a tight-fill connection between the tank and the delivery hose.

• Deliveries must be made by gravity only. If a delivery is made under pressure (pumped)
and the shutoff valve activates, something is likely to break.

North Dakota UST Operator Training Program Spill and Overfill Control 8
Overfill Prevention

Electronic Alarms

Of the three available overfill prevention technologies, electronic

alarms are the most versatile. Alarms may be used with tanks that
receive pumped or gravity deliveries and with tight-fill or loose-fill
connections. This type of overfill device activates an audible and/or
visual warning to delivery personnel when the tank reaches 90% full.

A typical overfill alarm can be tied into an automatic tank gauging

(ATG) system or a console. The ATG or console should have the ability
to trigger a remote alarm. The electronic alarm must be placed in an
area that will alert delivery personnel when the tank is no more than
90% full.

North Dakota UST Operator Training Program Spill and Overfill Control 9
Overfill Prevention

Electronic Alarms

An Electronic Alarm-

• Uses a float sensor that triggers an alarm when the tank reaches 90% full.

• Has NO mechanism to shut off or restrict flow.

• Should be activated once a year as part of a functionality test.

[NOTE: While it is NOT an overfill-prevention device by itself, an ATG will also likely sound a beep
when the outdoor alarm goes off.]

The fuel delivery driver must be able to see and hear the alarm while filling the tank. When the
driver hears the alarm, they should close the valve at the tanker and drain the delivery hose into
the tank.

REMEMBER - it is the responsibility of the owner and operator to ensure the volume available in
the tank is greater than the volume of the product to be transferred to the tank before the
transfer is made. Likewise, it is the responsibility of the owner and operator to monitor the
delivery, at all times, to prevent overfilling and spilling.

North Dakota UST Operator Training Program Spill and Overfill Control 10
Overfill Prevention

Electronic Alarms

This unit, which should be

located outside the
building and near the tank
field, contains a red light
and a horn. The unit is
connected to the ATG panel
and should give a visual
and audible warning when
the UST if filled to 95% of
its capacity.

The bell in this photograph is

another form of an alarm that
can be used for overfill
compliance.

North Dakota UST Operator Training Program Spill and Overfill Control 11
Overfill Prevention

Ball-Float Valves (Float-Vent Valves)

Ball floats consist of a short length of pipe that extends down into the Vent line
top of the tank from the vent opening. Typically, a wire cage containing
a hollow ball is fastened to the lower end of the pipe. The ball sits
below the end of the pipe within the wire cage.
Ball float
As long as the product level is below that of the ball, the tank vent pipe
remains open and the tank can “breathe” or maintain vapor flow. If the
fuel level is too high, the ball floats up and blocks the vent opening.
With the vent blocked, the flow rate of the delivery will decrease
noticeably and should alert the delivery person to close the valve at the
tanker and drain the delivery hose into the tank

[NOTE: The Underground Storage Tank rules require the ball-float

device to be set to operate at 90% of full tank volume.]

Every opening along the tank top must be tight for the ball-float vent
Ball float
valve to work properly. An open cap (ATG probe riser, gauging riser, blocks the vent
spare riser or stub out) allows vapors to escape at ground level and line
prevents pressure from building in the tank.
Fuel in tank

North Dakota UST Operator Training Program Spill and Overfill Control 12
Overfill Prevention

Ball-Float Valves (Float-Vent Valves)

Owners of tank systems that use ball-float vent devices should be aware
of the following situations that create extremely hazardous conditions:

DO NOT Use Ball-Float Devices…

• On tanks that receive pressurized (pumped) deliveries: The tank may

become over pressurized, causing it to rupture.

• On tanks with remote fills and gauge openings: Fuel may escape through
the gauge opening if the tank is overfilled.

• On tanks with suction pumps: When the ball float closes off the vent pipe,
pressure builds in the tank and a fuel overfill will escape from the pump at
the dispenser.

• On tanks with loose fills: If the delivery hose is not tightly clamped to the
tank fill pipe, fuel will back up the fill pipe and spill onto the ground when
the ball-float valve closes.

• On generator or heating oil tanks: These types of tanks very often have
pumped deliveries and loose-fill connections, two things that are not
compatible with ball-float valves. Ball-float valve

North Dakota UST Operator Training Program Spill and Overfill Control 13
Overfill Prevention

Ball-Float Valves (Float-Vent Valves)

The ball-float valve should periodically be checked by a service technician to make sure it is
functioning properly and that it will restrict fuel flowing into the tank at 90% of the tank capacity:

• Ensure that the ball-float valve is not plugged.

• Make sure the ball cage is intact.

• Ensure the ball still moves freely in the cage.

• Make sure the ball still seals tightly on the pipe.

REMEMBER - it is the responsibility of the owner and operator to ensure the volume available in
the tank is greater than the volume of the product to be transferred to the tank before the transfer
is made. Likewise, it is the responsibility of the owner and operator to monitor the delivery at all
times to prevent overfilling and spilling.

North Dakota UST Operator Training Program Spill and Overfill Control 14